ESAB Mig 4002c Manual de usuario

US

Valid for serial no. 946-xxx-xxxx, 947-xxx-xxxx,

948-xxx-xxxx

0463 299 087 US 20111102

Origo™

Mig 4002c

Mig 5002c

Mig 6502c

Instruction manual

- 2 -

- 3 -

TOCa

Rights reserved to alter specifications without notice.

1 USER RESPONSIBILITY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY PRECAUTIONS - English 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PRECAUCION DE SEGURIDAD - Spanish 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 MESURES DE SECURITE - French 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 SAFETY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Placing 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Assembly of components 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Mains power supply 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23. . . .

5 OPERATION 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections and control devices 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Overheating protection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT TRACING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCHEMATIC DIAGRAM 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCHEMATIC DIAGRAM 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 4 -

US warnings

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding equipment, we urge you to read

our booklet, “Precations and Safe Practices for Arc, Cutting and Gouging, “Form 52-529.

Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT

attempt to install or operate this equipment until you have read and fully understand these

instructions. If you do not fully understand these instructions, contact your supplier for

further information. Be sure to read the Safety Precautions before installing or operating

this equipment.

1 USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and

accompanying labels and/or insert when installed, operated, maintained and repaired in accordance

with the instruction provided. This equipment must be checked periodically. Malfunctioning or poorly

maintained equipment should not be used. Parts that are broken, missing, worn, distorted or

contaminated should be replaced immediately. Should such repair or replacement become necessary,

the manufacturer recommends that a telephone or written request for service advice be made to the

Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the

manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which

results from improper use, faulty maintenance, damage improper repair or alteration by anyone other

than the manufacturer or a service facility designated by the manufacturer.

2 SAFETY PRECAUTIONS - English

WARNING: These Safety Precautions are for your protection. They summarize precautionary

information from the references listed in 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 Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging precesses are noisy and require ear

protection. The arc, like the sun, emits ultraviolet (UV) and other radiation

and can injure 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. Always wear safety glasses with side shields in any work area, even if welding helmets face

shields and goggles are also required.

2. 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 watch the arc and not to expose themselves to the rays of the electric-arc or

hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, 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.

US

- 5 -

US warnings

4. 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 clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable nonflammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and

can fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS

Heat from flames and arcs can start fires. Hot slag or sparks can also cause

fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a

protective nonflammable covering. Combusible materials include wood, clot, sawdust, liquid and

gas fuels, solvents, pants and coatings papper, etc.

2. 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.

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so

that there are no substances on the workpiece which might produce flammable or toxic vapors.

Do not do hot work on closed containers. They may explode.

4. 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.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat

and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot

metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and

Welding Processes”, available from the National Fire Protection Association, Batterymarch Park,

Quincy, MA 02269.

ELECTRICAL SHOCK

Contact with live electrical parts and ground 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 ground system of the input power.

2. Connect the workpiece to a good electrical ground.

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 bady are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear rubber-soled shoes.

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 (listed on next page) for specific grounding

recommendations. Do not mistake the work lead for a ground cable.

US

- 6 -

US warnings

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding and cutting current

creates EMF around welding cables and welding machines.

Therefore:

1. Welders having pacemakers should consult their physician 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 minimize 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 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. Do not breathe fumes and gases. Shielding gases can cause

asphyxiation.

Therfore:

1. 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, cooper, zinc, lead

beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes

from these materials.

2. 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.

3. If you develop momentary eye, nose or throat irritation while operating, this is an indication that

ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

5. WARNING: This product when used for welding or cutting, produces fumes or gases which

contain chemicals known to the State of Californa to cause birth defects and in some cases

cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. Sudden

rupture of cylinder valve or relief device can injure or kill.

Therefore:

1. 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 adaptors. Maintain hoses and fittings in

good condition. Follow manufacturer's operating instructions for mounting regulator to a

compressed gas cylinder.

2. 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.

3. 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.

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

5. For additional information, refer to CGA Standard P-1, “Precations for Safe Handling of

Comporessed Gases in Cylinders”, which is available from Compressed Gas Association, 1235

Jefferson Davis Highway, Arlington, VA 22202.

US

- 7 -

US warnings

EQUIPMENT MAINTENANCE

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

1. Always have qualified personnel perform the installaion, 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, grounding 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.

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, which are available from the American Welding Society, 550 N.W. LeJuene

Road, Miami, FL 33126, are recommended to you:

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

2. AWS C5.1 . “Recommended Practices for Plasma Arc Welding”

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“

4. AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

7. AWS SP - “Safe practices” - Reprint, Welding Handbook

8. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That

Have Held Hazardous Substances”

MEANING OF SYMBOLS

As used throughout this manual: Means Attention! Be Alert!

Means immediate hazards which, if not avoided, will result in

immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss

of life.

Means hazards which could result in minor personal injury.

US

- 8 -

US warnings

3 PRECAUCION DE SEGURIDAD - Spanish

ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen

resumen de información proveniente de las referencias listadas en la sección ”Información Adicional

Sobre La Seguridad”. Antes de hacer cualquier instalación o procedimiento de operación, asegúrese

de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual,

hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de

Seguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS

Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren

protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV)

y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente

causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus

procesos es esencial para prevenir accidentes.

Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún

cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de

las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a

todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o

el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo

liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo

de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a

prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa, el

ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al

frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada

no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o

puliendo. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas

deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES

El calor de las flamas y el arco pueden ocacionar fuegos. Escoria caliente y

las chispas pueden causar fuegos y explosiones.

Por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una

cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases

flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes

causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y

agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté

totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores

tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si

contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una

manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted

esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable

sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de

que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para

vigilar si es necesario.

US

- 9 -

US warnings

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, “Fire

Prevention in Use of Cutting and Welding Processes”, available from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO

El contacto con las partes eléctricas energizadas y tierra puede causar daño

severo o muerte. NO use soldadura de corriente alterna (AC) en áreas

húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad

de caer al suelo.

Por lo tanto:

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de

electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas

conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con

conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del

electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y

tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas

húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con

suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. RUse como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página)

para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de

soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS

Son peligrosos. La corriente eléctrica fluye através de cualquier conductor

causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las

corrientes en el área de corte y soldadura, crean EMF alrrededor de los

cables de soldar y las maquinas.

Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico

antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marcapasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún

desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

a. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que

usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

b. Nunca envuelva los cables de soldar alrededor de su cuerpo.

c. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los

cables a un sólo lado de su cuerpo.

d. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la

soldadura.

e. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.

US

- 10 -

US warnings

HUMO Y GASES

El humo y los gases, pueden causar malestar o daño, particularmente en

espacios sin ventilación. No inhale el humo o gases. El gas de protección

puede causar falta de oxígeno.

Por lo tanto:

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No

solde, corte, o trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con

hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea

ventilación mecánica positiva. No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los

rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un

fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando,

es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas

necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el

malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para

recomendaciones específicas en la ventilación.

5. ADVERTENCIA-Este producto cuando se utiliza para soldaduras o cortes, produce humos o

gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos

en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et

seq.)

MANEJO DE CILINDROS

Los cilindros, si no son manejados correctamente, pueden romperse y liberar

violentamente gases. Rotura repentina del cilindro, válvula, o válvula de

escape puede causar daño o muerte.

Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la

presión del cilindro de gas. No utilice adaptadores. Mantenga las mangueras y las conexiones en

buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el

regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena

adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón.

Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de

soldadura. Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de

protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros

utilizando un carro o transporte adecuado. Evite el manejo brusco de los

4. Localize los cilindros lejos del calor, chispas, y flamas. Nunca establezca un arco en el cilindro.

5. Para información adicional, haga referncia a la publicación CGA Standard P-1, “Precations for

Safe Handling of Comporessed Gases in Cylinders”, disponible através del Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

MANTENIMIENTO DEL EQUIPO

Equipo defectuoso o mal mantenido puede causar daño o muerte.

Por lo tanto:

1. Siempre tenga personal cualificado para efectuar la instalación, diagnóstico, y mantenimiento del

equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el

trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder

del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder

en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor

como hornos, también lugares húmedos como charcos de agua, aceite o grasa, atmósferas

corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas

condiciones.

US

- 11 -

US warnings

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna

manera.

INFORMACION ADICIONAL DE SEGURIDAD

Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico

para soldar y cortar, pregunte a su suplidor por una copia de “Precautions and Safe

Practices for Arc Welding, Cutting and Gouging”, Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene

Road, Miami, FL 33126, son recomendadas para usted:

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

2. AWS C5.1 . “Recommended Practices for Plasma Arc Welding”

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“

4. AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

7. AWS SP - “Safe practices” - Reprint, Welding Handbook

8. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That

Have Held Hazardous Substances”

SIGNIFICADO DE LOS SIMBOLOS

Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡Atención!

¡Esté Alerta! Se trata de su seguridad.

Significa riesgo inmediato que, de no ser evadido, puede resultar

inmediatamente en serio daño personal o la muerte.

Significa el riesgo de un peligro potencial que puede resultar en serio

daño personal o la muerte.

Significa el posible riesgo que puede resultar en menores daños a la

persona.

US

- 12 -

US warnings

4 MESURES DE SECURITE - French

ATTENTION : ces règles de sécurité ont pour objet d'assurer votre protection. Elles constituent

une synthèse des mesures de sécurité contenues dans les ouvrages de référence repris au chapitre

Informations complémentaires relatives à la Sécurité. Avant toute installation ou utilisation du matériel,

veillez à lire et à respecter les règles de sécurité énoncées ci-dessous ainsi que dans les divers

manuels, fiches de sécurité du matériel, étiquettes, etc. Le non-respect de ces précautions risque

d'entraîner des blessures graves ou mortelles.

PROTECTION INDIVIDUELLE ET DE L'ENTOURAGE

Certains procédés de soudage, découpage et gougeage sont bruyants et

requièrent le port de protections auditives. L'arc, tout comme le soleil, émet

des ultraviolets (UV) et d'autres rayonnements susceptibles de provoquer des

lésions oculaires et dermatologiques. Le métal chaud peut être à l'origine de

brûlures. Une formation à l'utilisation correcte des procédés et équipements

est essentielle pour prévenir les accidents. En conséquence :

1. Porter impérativement des lunettes avec écrans latéraux dans les zones de travail, même

lorsque le port du casque de soudage, de l'écran facial et des lunettes de protection est

obligatoire

2. Tant pour exécuter les travaux que pour y assister, porter un écran facial muni de plaques

protectrices et de verres filtrants appropriés pour protéger les yeux, le visage, le cou et les

oreilles des étincelles et du rayonnement de l'arc. Avertir les personnes se trouvant à proximité

qu'elles ne doivent pas regarder l'arc, ni s'exposer à son rayonnement ou à celui du métal

incandescent.

3. Porter des gants ignifuges à crispins, une tunique épaisse à longues manches, des pantalons

sans rebord, des chaussures à embout d'acier et un casque de soudage ou une casquette pour

se protéger du rayonnement de l'arc, des étincelles et du métal incandescent. Le port d'un tablier

ininflammable est également recommandé afin de se protéger des étincelles et du rayonnement

thermique.

4. Les étincelles ou projections de métal en fusion risquent de se loger dans les manches

retroussées, les bords relevés de pantalons ou dans les poches. Il convient donc de boutonner

complètement les manches et le col, et de porter des vêtements sans poches à l'avant.

5. Protéger du rayonnement de l'arc et des étincelles les personnes se trouvant à proximité à l'aide

d'un écran ou d'un rideau ininflammable approprié.

6. Porter des oculaires et des lunettes de protection pendant le meulage du laitier. Les particules

meulées, souvent brûlantes, peuvent être projetées à des distances importantes, de sorte que

les personnes se trouvant à proximité doivent également porter des lunettes de protection.

INCENDIES ET EXPLOSIONS

La chaleur dégagée par les flammes et les arcs peuvent être à l'origine

d'incendies. Le laitier incandescent et les étincelles peuvent également

provoquer incendies et explosions. En conséquence :

1. Éloigner suffisamment tous les matériaux combustibles de la zone de travail ou les recouvrir

complètement d'une bâche ignifuge. Ce type de matériaux comprend le bois, les vêtements, la

sciure, les carburants sous forme liquide et gazeuse, les peintures, les enduits, le papier, etc.

2. Les étincelles ou projections de métal en fusion peuvent tomber dans les fissures du sol ou des

murs et déclencher une combustion lente dans les planchers ou à l'étage inférieur. Veiller à

protéger ces ouvertures pour que les étincelles et projections n'y pénètrent pas.

3. Ne pas procéder à des travaux de soudage, de découpage et autres travaux à chaud tant que la

surface n'est pas complètement nettoyée et débarrassée des substances susceptibles de

produire des vapeurs inflammables ou toxiques. Ne pas effectuer de travaux à chaud sur des

conteneurs fermés pour éviter tout risque d'explosion.

4. Conserver à portée de main un équipement d'extinction – tuyau d'arrosage, seau d'eau ou de

sable, extincteur portatif, etc. et s'assurer d'en connaître l'utilisation.

5. Ne pas utiliser l'équipement au-delà de ses spécifications. Par exemple, un câble de soudage

surchargé est susceptible de surchauffer et d'être à l'origine d'un incendie.

US

- 13 -

US warnings

6. Une fois le travail terminé, inspecter la zone de travail pour s'assurer qu'aucune étincelle ou

projection de métal ne risque de déclencher un incendie. Le cas échéant, utiliser des systèmes

de détection d'incendie.

7. Pour toute information supplémentaire, voir la norme NFPA 51B relative à la prévention des

incendies lors de travaux de découpage et de soudage, disponible auprès de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269 – USA.

CHOC ELECTRIQUE

Tout contact avec des éléments sous tension et la masse peut provoquer des

blessures graves ou mortelles. NE PAS utiliser de courant de soudage CA

dans des zones humides, des lieux exigus ou lorsqu'il existe un risque de

chute. En conséquence :

1. Vérifier que le châssis du générateur est bien relié au dispositif de mise à la masse de

l'alimentation.

2. Assurer une mise à la masse correcte de la pièce à souder.

3. Connecter le câble de soudage à la pièce à souder. Un raccordement médiocre ou inexistant

constitue un risque mortel pour l'utilisateur et son entourage.

4. Utiliser du matériel correctement entretenu. Remplacer les câbles usés ou endommagés.

5. Empêcher l'apparition de toute humidité, notamment sur les vêtements, dans la zone de travail,

sur les câbles, la torche de soudage, le porte-électrode et le générateur.

6. S'assurer que le corps est totalement isolé de la pièce à souder et de la masse.

7. Éviter tout contact direct avec du métal ou la masse lors de travaux dans des endroits exigus et

en zone humide ; se tenir sur des panneaux ou sur une plate-forme isolante et porter des

chaussures à semelles en caoutchouc.

8. Enfiler des gants secs et sans trous avant de mettre l'équipement sous tension.

9. Mettre l'équipement hors tension avant de retirer les gants.

10. Voir la norme ANSI/ASC Z49.1 (voir page suivante) pour les recommandations de mise à la

masse. Ne pas confondre le câble de soudage et le câble de masse.

CHAMPS ELECTRIQUES ET MAGNETIQUES

Danger. Le courant électrique parcourant les conducteurs génère localement

des champs électriques et magnétiques (EMF). Le courant de soudage et de

découpe crée des EMF autour des câbles de soudage et des postes à souder.

En conséquence :

1. Les porteurs de stimulateurs cardiaques consulteront leur médecin avant d'effectuer des travaux

de soudage. Les EMF peuvent en effet provoquer des interférences.

2. L'exposition aux EMF peut également avoir des effets méconnus sur la santé.

3. Les soudeurs respecteront les procédures suivantes pour réduire l'exposition aux EMF :

a. Rassembler en faisceau les câbles de soudage et d'électrode. Si possible, les attacher avec

du ruban adhésif.

b. Ne jamais enrouler le câble de la torche ou le câble de soudage autour du corps.

c. L'utilisateur ne doit jamais se trouver entre le câble de la torche et le câble de soudage.

Faire passer tous les câbles du même côté du corps.

d. Connecter le câble de soudage à la pièce à souder, au plus près de l'endroit du soudage.

e. S'éloigner au maximum du générateur et des câbles.

US

- 14 -

US warnings

FUMEES ET GAZ

L'inhalation des fumées et gaz peut provoquer des malaises et des

dommages corporels, surtout lors de travaux dans les espaces confinés. Ne

pas les respirer. Les gaz inertes peuvent causer l'asphyxie.

En conséquence :

1. Assurer une aération adéquate de la zone de travail par une ventilation naturelle ou mécanique.

Ne pas effectuer de travaux de soudage, découpage ou gougeage sur des matériaux tels que

l'acier galvanisé, le cuivre, le zinc, le plomb, le béryllium et le cadmium en l'absence d'une

ventilation mécanique adéquate. Ne pas inhaler les fumées dégagées par ces matériaux.

2. Ne pas travailler à proximité d'opérations de dégraissage et de pulvérisation étant donné que la

chaleur dégagée et l'arc peut réagir avec les hydrocarbures chlorés pour former du phosgène –

un gaz particulièrement toxique – et d'autres gaz irritants.

3. Une irritation momentanée des yeux, du nez ou de la gorge provoquée par les travaux est le

signe d'une ventilation inappropriée. Dans ce cas, il convient d'arrêter le travail et de prendre les

mesures nécessaires pour améliorer l'aération. Ne pas poursuivre le travail si le malaise persiste.

4. Voir la norme ANSI/ASC Z49.1 (voir ci-dessous) pour les recommandations de ventilation.

5. ATTENTION : utilisé dans des opérations de soudage et de découpage, ce produit dégage des

fumées et gaz qui contiennent des substances chimiques reconnues par l'État de Californie

comme pouvant être à l'origine de malformations congénitales et de cancers (California Health &

Safety Code §25249.5 et seq.).

MANIPULATION DES BOUTEILLES DE GAZ

Une erreur de manutention des bouteilles de gaz peut les endommager et

entraîner une libération violente du gaz. La rupture soudaine de la soupape

ou du détendeur peut provoquer des blessures graves ou mortelles.

En conséquence :

1. Utiliser le gaz approprié à la pression adéquate, celle-ci étant réglée par un détendeur adapté au

type de bouteille utilisée. Ne pas utiliser d'adaptateurs. Garder les tuyaux et accessoires en bon

état. Pour le montage du détendeur sur une bouteille de gaz comprimé, suivre les instructions du

fabricant.

2. Fixer les bouteilles verticalement – au moyen d'une chaîne ou d'une sangle – à un chariot à bras,

un châssis de roulement, un banc, un mur, un piquet ou un rack. Ne jamais attacher les

bouteilles aux établis et éléments susceptibles de les intégrer à un circuit électrique.

3. Conserver les bouteilles fermées lorsqu'elles ne sont pas utilisées. Les fermer par un bouchon

lorsqu'elles ne sont pas raccordées. Attacher et déplacer les bouteilles à l'aide de chariots

adéquats.

4. Éloigner les bouteilles des sources de chaleur, d'étincelles et de flammes nues. Ne jamais

déclencher d'arc sur une bouteille de gaz.

5. Pour plus d'informations sur les précautions d'utilisation des bouteilles de gaz comprimé, voir la

norme CGA P-1, disponible auprès de la Compressed Gas Association, 1235 Jefferson Davis

Highway, Arlington, VA 22202 – USA.

ENTRETIEN DE L'EQUIPEMENT

Un équipement mal entretenu peut provoquer des blessures graves ou mortelles. En

conséquence :

1. Confier l'installation, les dépannages et l'entretien à du personnel qualifié. Ne pas effectuer de

travaux électriques si vous ne possédez pas les compétences requises.

2. Mettre l'équipement hors tension avant toute intervention d'entretien sur le générateur.

3. Maintenir en bon état de fonctionnement les câbles, câbles de masse, connexions, cordons

d'alimentation et générateurs. Ne jamais utiliser d'équipements défectueux.

4. Ne jamais surcharger les équipements et accessoires. Conserver les équipements à l'écart des

sources de chaleur – notamment des fours –, des flaques d'eau, des traces d'huile ou de graisse,

des atmosphères corrosives et des intempéries.

5. Laisser en place tous les dispositifs de sécurité et tous les panneaux du tableau de commande

en veillant à les garder en bon état.

6. Utiliser l'équipement conformément à l'usage prévu ; n'y apporter aucune modification

quelconque.

US

- 15 -

US warnings

INFORMATIONS COMPLEMENTAIRES RELATIVES A LA SECURITE Pour plus

d'informations relatives aux règles de sécurité pour les travaux de gougeage, de

découpage et de soudage à l'arc électrique, demander au fournisseur une copie du

formulaire 52/529.

L'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 – USA, publie les documents

suivants dont la lecture est également recommandée :

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

2. AWS C5.1 . ”Recommended Practices for Plasma Arc Welding”

3. AWS C5.2 - ”Recommended Practices for Plasma Arc Cutting”

4. AWS C5.3 - ”Recommended Practices for Air Carbon, Arc Gouging and Cutting”

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

6. AWS C5.6 - ”Recommended Practices for Gas Metal Arc welding”

7. AWS SP - ”Safe practices” - Réédition, Manuel de soudage

8. ANSI/AWS F4.1 - ”Recommended Safe Practices for Welding and Cutting of Containers That

Have Held Hazardous Substances”

SYMBOLES

Signification des symboles utilisés dans ce manuel : = Attention ! Rester prudent !

= danger immédiat ; risque de blessures graves ou mortelles.

= danger potentiel ; risque de blessures graves ou mortelles.

= danger ; risque de blessures légères.

US

- 16 -

ba57da

1 SAFETY

Users of ESAB welding 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 welding equipment. The following recommen

dations 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 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 be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the ground cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

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, which are available from the American Welding Society, 550 N.W. LeJuene

Road, Miami, FL 33126, are recommended to you:

US

- 17 -

ba57da

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUSIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES

WHICH SHOULD BE BASED ON MANUFACTURERS' HAZARD DATA.

ELECTRIC SHOCK - CAN KILL

S INSTALL AND EARTH THE WELDING UNIT IN ACCORDANCE WITH APPLICABLE

STANDARDS.

S DO NOT TOUCH LIVE ELECTRICAL PARTS OR ELECTRODES WITH BARE SKIN,

WET GLOVES OR WET CLOTHING.

S INSULATE YOURSELF FROM EARTH AND THE WORKPIECE.

S ENSURE YOUR WORKING STANCE IS SAFE.

FUMES AND GASES - CAN BE DANGEROUS TO HEALTH

S KEEP YOUR HEAD OUT OF THE FUMES.

S 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.

S PROTECT YOUR EYES AND BODY. USE THE CORRECT WELDING SCREEN AND

FILTER LENS AND WEAR PROTECTIVE CLOTHING.

S PROTECT BYSTANDERS WITH SUITABLE SCREENS OR CURTAINS.

FIRE HAZARD

S SPARKS (SPATTER) CAN CAUSE FIRE. MAKE SURE THEREFORE THAT THERE ARE

NO INFLAMMABLE MATERIALS NEARBY.

NOISE - EXCESSIVE NOISE CAN DAMAGE HEARING

S PROTECT YOUR EARS. USE EARMUFFS OR OTHER HEARING PROTECTION.

S WARN BYSTANDERS OF THE RISK.

MALFUNCTION - CALL FOR EXPERT ASSISTANCE IN THE EVENT OF MALFUNCTION.

PROTECT YOURSELF AND OTHERS!

DO NOT USE THE POWER SOURCE FOR THAWING FROZEN PIPES.

This product is solely intended for arc welding. Any other use may result in personal

injury and / or equipment damage.

US

- 18 -

ba57da

Read and understand the instruction manual

before installing or operating.

ESAB can provide you with all necessary welding protection and accessories.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/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.

2 INTRODUCTION

The Mig 4002cw, Mig 5002cw, Mig 6502cw are MIG/MAG welding power sources,

which can also be used for MMA welding.

Different variants of the power sources see page 41.

The power sources are intended for use with the Feed 3004, Feed 4804 or

YardFeed 2000 wire feed units.

All settings are made from the wire feed unit.

ESAB's accessories for the product can be found on page 42.

2.1 Equipment

The power source is supplied with:

S Return cable 5m with return clamp

S Shelf for gas cylinder

S Attachment chain for gas cylinder

S Guide pin for wire feed unit

S Instruction manual

US

- 19 -

ba57da

3 TECHNICAL DATA

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

Efficiency 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

Transportation temperature -20 to +55° C

Enclosure class IP 23

Application classification

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

Efficiency 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

Transportation temperature -20 to +55° C

US

- 20 -

ba57da

MIG 5002cw

Enclosure class IP 23

Application classification

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

Efficiency 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

Transportation temperature -20 to +55° C

Enclosure class IP 23

Application classification

Cooling unit

Cooling power 1100 W at 25° C and flow 1 l/min

Coolant ESAB's ready mixed coolant

Coolant quantity 5 l

Maximum flow 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 at a cer

tain load without overloading. The duty cycle is valid for 104° F.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

US

- 21 -

ba57da

4 INSTALLATION

The installation must be done by a professional.

STRAPS MUST BE USED WHEN LIFTING

THE POWER SOURCE. THE HANDLE IS

ONLY INTENDED FOR PULLING IT.

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 so that its cooling air inlets and outlets are not

obstructed.

US

- 22 -

ba57da

4.2 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!

US

- 23 -

ba57da

4.3 Mains power supply

US

- 24 -

ba57da

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 earth connection must be made,

in accordance with regulations.

Rating plate with supply

connection data

US

- 25 -

ba57da

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 mm

2

16/6/6 mm

2

25/10/10 mm

2

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 mm

2

16/6/6 mm

2

25/10/10 mm

2

Fuse anti-surge 35/25(50*)/20 A 63/35(50*)/35 A 80/50(63*)/50 A

* AAG (Arc Air Gouging)

NB: 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.

5 OPERATION

General safety regulations for the handling of the equipment can be found on

page 4. Read through before you start using the equipment!

FASTEN THE EQUIPMENT - PARTICULARLY IF

THE GROUND IS UNEVEN OR SLOPING.

US

- 26 -

ba57da

US

- 27 -

ba57da

5.1 Connections and control devices

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

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

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

wire feed unit

4 Connection for weldng current cable (+) 9 Connection RED for cooling water from

the wire feed unit

5 Connection for weldng current cable (-)

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.

6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates.

Supplier warranty is void if customer attempts any work on product during the

warranty period.

US

- 28 -

ba57da

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 page 31. 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 on page 42.

6.1.2 Welding gun

Wear parts should be cleaned and replaced at regular intervals in order to achieve

trouble-free welding.

6.2 Topping up the coolant

ESAB ready mixed coolant is recommended for use.

See accessories on page 42.

S Fill with coolant.

(The fluid level must not exceed the upper marking

but neither must it be below the lower marking).

S Disconnect the coolant hose for outgoing water

(welding gun blue connection) in order to

bleed any trapped air.

S Connect the coolant hose again.

Note! Coolant must be topped up if connecting a

welding gun 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.

The coolant must be handled as chemical waste.

US

- 29 -

ba57da

7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised

service technican.

Type of fault Actions

No arc. S Check that the mains power supply switch is turned on.

S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.

Welding current is interrupted

during welding

S Check whether the thermal overload trip has operated

(indicated by the orange lamp on the front)

S Check the main power supply fuses.

The thermal overload trips

operate frequently

S Check to see whether the air filters are clogged.

S 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. S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.

S Check that the correct welding wires are being used.

S Check the main power supply fuses.

8 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB service

personnel. Use only ESAB original replacement and wear parts.

Mig 4002C, Mig 5002C, Mig 6502C is designed and tested in accordance with the inter

national and European standards EN 60974-1 and EN 60974-10. It is the obligation of

the service unit which has carried out the service or repair work to make sure that the

product still conforms to the said standard.

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 on

which the parts will be used. The serial number is stamped on the rating plate.

US

- 30 -

notes

NOTES

.............................................................................................................................................................

Cleaning

- 31 -

ba57clean

Schematic diagram

ERRATA

- 32 -

dmxx02cw

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

- 33 -

dmxx02cw

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

- 34 -

dmxx02cw

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

- 35 -

dmxx02cw

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

- 36 -

dmxx02cw

Mig 4002cw, 5002cw, 6502cw, 230 - 500 V

- 37 -

dmxx02cw

Mig 4002cw, 5002cw, 6502cw, 230 - 500 V

- 38 -

dmxx02cw

Mig 4002c, 5002c, 6502c, 230 - 500 V

- 39 -

dmxx02cw

Mig 4002c, 5002c, 6502c, 230 - 500 V

- 40 -

vrxx02c

Schematic diagram

Mig 4002c, Mig 5002c, Mig 6502c

Ordering number

- 41 -

omxx02cw

Valid for serial no. 946-xxx-xxxx, 947-xxx-xxxx, 948-xxx-xxxx-XXX-XXXX

Ordering numbers

0349 309 780 Origo

TM

Mig 4002cw 400V - 415V, 3~50Hz; with water cooler 740

0349 311 300 Origo

TM

Mig 4002c 400V - 415V, 3~50Hz 743

0349 311 350 Origo

TM

Mig 5002cw 400V - 415V, 3~50Hz; with water cooler 741

0349 311 330 Origo

TM

Mig 5002c 400V - 415V, 3~50Hz 744

0349 311 390 Origo

TM

Mig 6502cw 400V - 415V, 3~50Hz; with water cooler 742

0349 311 370 Origo

TM

Mig 6502c 400V - 415V, 3~50Hz 745

0349 311 320 Origo

TM

Mig 4002cw 230V - 500V, 3~50Hz, 3~60Hz; with water cooler 801

0349 311 310 Origo

TM

Mig 4002c 230V - 500V, 3~50Hz, 3~60Hz 802

0349 311 360 Origo

TM

Mig 5002cw 230V - 500V, 3~50Hz, 3~60Hz; with water cooler 803

0349 311 340 Origo

TM

Mig 5002c 230V - 500V, 3~50Hz, 3~60Hz 804

0349 311 400 Origo

TM

Mig 6502cw 230V - 500V, 3~50Hz, 3~60Hz; with water cooler 806

0349 311 380 Origo

TM

Mig 6502c 230V - 500V, 3~50Hz, 3~60Hz 805

0349 312 040 Origo

TM

Mig 4002c 230V - 500V, 3~50Hz, 3~60Hz; with panel A24 802

Mig 4002c, Mig 5002c, Mig 6502c

Accessories

- 42 -

amx2c

Origo

TM

Feed

MA23 panel

Origo

TM

Feed 3004 . . . . . . . . . . . . . . . . . . . . . . . .

Origo

TM

Feed 3004 W, with water . . . . . . . . . . .

Origo

TM

Feed 4804 . . . . . . . . . . . . . . . . . . . . . . . .

Origo

TM

Feed 4804 W, with water . . . . . . . . . . .

MA24 panel

Origo

TM

Feed 3004 . . . . . . . . . . . . . . . . . . . . . . . .

Origo

TM

Feed 3004 W, with water . . . . . . . . . . .

Origo

TM

Feed 4804 . . . . . . . . . . . . . . . . . . . . . . . .

Origo

TM

Feed 4804 W, with water . . . . . . . . . . .

0460 526 887

0460 526 897

0460 526 987

0460 526 997

0460 526 889

0460 526 899

0460 526 989

0460 526 999

Aristo

TM

Feed

U6 panel

Aristo

TM

Feed 3004 . . . . . . . . . . . . . . . . . . . . . . . .

Aristo

TM

Feed 3004 W, with water . . . . . . . . . . .

Aristo

TM

Feed 4804 . . . . . . . . . . . . . . . . . . . . . . . .

Aristo

TM

Feed 4804 W, with water . . . . . . . . . . .

U8 panel

Aristo

TM

Feed 3004 . . . . . . . . . . . . . . . . . . . . . . . .

Aristo

TM

Feed 3004 W, with water . . . . . . . . . . .

Aristo

TM

Feed 4804 . . . . . . . . . . . . . . . . . . . . . . . .

Aristo

TM

Feed 4804 W, with water . . . . . . . . . . .

0460 526 886

0460 526 896

0460 526 986

0460 526 996

0460 526 881

0460 526 891

0460 526 981

0460 526 991

Origo

TM

YardFeed 2000

MA23 panel

Origo

TM

YardFeed 2000 . . . . . . . . . . . . . . . . . . . .

Origo

TM

YardFeed 2000 W, with water . . . . . . .

Aristo

TM

YardFeed 2000

MA6 panel

Aristo

TM

YardFeed 2000 . . . . . . . . . . . . . . . . . . .

Aristo

TM

YardFeed 2000 W, with water . . . . . . .

0459 906 887

0459 906 897

0459 906 886

0459 906 896

Transformer for CO

2

heater . . . . . . . . . . . . . . . 0349 302 250

Mig 4002c, Mig 5002c, Mig 6502c

- 43 -

amx2c

Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . 0349 302 251

Coolant Ready mixed (5l) . . . . . . . . . . . . . . . . . 0349 483 296

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0349 302 252

Holder for welding gun and cables . . . . . . . . 0349 303 362

Adapter (12 Burndy <-> 10 Amphenol) . . . . . 0349 311 512

Mig 4002c, Mig 5002c, Mig 6502c

- 44 -

amx2c

Strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0349 311 700

Connection set for 400 A power sources,

50mm

2

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 . . . . . . . . . . . . . . . . .

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 for 500 A power sources,

70mm

2

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 . . . . . . . . . . . . . . . . .

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 for 650 A power sources,

95mm

2

Connection set 1.7 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 . . . . . . . . . . . . . . . . .

0459 528 980

0459 528 990

0459 528 991

0459 528 992

0459 528 993

0459 528 994

For more information of the accessories contact the nearest ESAB agency.

- 45 -

notes

NOTES

.............................................................................................................................................................

www.esab.com

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 745 11 28

BULGARIA

ESAB Kft Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Bareggio (Mi)

Tel: +39 02 97 96 8.1

Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V.

Amersfoort

Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

NORWAY

AS ESAB

Larvik

Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL

Bucharest

Tel: +40 316 900 600

Fax: +40 316 900 601

RUSSIA

LLC ESAB

Moscow

Tel: +7 (495) 663 20 08

Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel: +421 7 44 88 24 26

Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB international AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC

Kiev

Tel: +38 (044) 501 23 24

Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific

Archerfield BC QLD 4108

Tel: +61 1300 372 228

Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 2326 3000

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd

Durbanvill 7570 - Cape Town

Tel: +27 (0)21 975 8924

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB Mig 4002c Manual de usuario

ESAB Mig 4002c Manual de usuario

en otros idiomas

Artículos relacionados