The ESAB Origo MIG 5002cw is a multiprocess power source in Chopper technology, with an Aristo U6 panel and a built in liquid cooler. The maker gives 500 A at a 60% duty cycle and 400 A at a 100% duty cycle, an adjustment range from 16 to 500 A and a supply of 400 V, 3 phases, 50 Hz. The housing has class IP23.
What this machine is for
The Chopper joins a massive transformer with a fast transistor switch, so you get arc dynamics close to an inverter with the toughness of a transformer design. In practice the arc holds even at abrupt changes of the free wire stick out, and hard short circuits are limited, which you see in the amount of spatter and in the use of wire and gas.
A current of 500 A at a 60% duty cycle and 400 A in continuous work is a range for heavy steel prefabrication: halls, bridges, crane parts, ship plating and internal ship structures, repairs of mining and construction machines, pipelines of large diameters and pressure vessels. The Aristo U6 panel with pulse opens the machine to aluminium and stainless steel, where the amount of heat put in counts.
Apart from MIG/MAG the machine welds with a covered electrode. At 500 A it will handle electrodes of 6 mm in diameter and larger, with the Hot Start function at ignition and Arc Force, which protects against the electrode sticking in forced positions. The same power reserve is enough for gouging with a carbon electrode, that is removing defects, preparing edges and welding from both sides.
The Aristo U6 panel has a clear display of the parameters and knobs with which you correct the arc length while welding. Ten memory channels are enough to assign settings to repeatable parts and to switch between them without setting the process up again. On top of that comes QSet, which after a few seconds of welding matches the dynamics of the short arc to the gas and the position by itself, instead of a manual search for the right inductance.
The cooler in the cw version is meant for work at currents above 400 A. It takes the heat from the torch, so the contact tips burn out more slowly and the neck of the torch does not deform from heat radiation. A steady temperature of the cables also means a steadier arc characteristic, because the resistance of a hot package does not rise in an uncontrolled way.
Features and equipment
- Chopper technology: electronic modulation of the output current with the transformer toughness against overloads, with a stable arc and less spatter.
- Aristo U6 panel: synergic lines for unalloyed and stainless steels and for aluminium alloys, a choice of wire, diameter and gas, and the controller sets the rest.
- 10 memory channels: you switch between tested settings without setting the process up again.
- Correction of the arc length with a knob while welding: control over the pool without breaking the bead.
- Pulsed MIG/MAG welding: controlled transfer of droplets and lower heat input, that is less distortion and a narrower heat affected zone, which on stainless steel helps to keep the corrosion resistance and on aluminium protects thin walls against burn through.
- QSet: the circuit analyses the frequency of short circuits in the first seconds of welding and matches the dynamics of the short arc to the gas and the position by itself, instead of a manual setting of the inductance.
- TrueArcVoltage: measurement of the voltage at the arc and correction of the settings of the power source, so that long earth and interconnection cables do not weaken the fusion.
- Built in liquid cooler with a flow sensor: it blocks welding when the pump fails or the coolant runs out, which protects the cable package.
- MMA mode with Hot Start and Arc Force: electrodes of 6 mm in diameter and larger.
- Gouging with a carbon electrode: welding repairs and edge preparation.
- Helper functions: gas flow before and after welding, burn back, creep start, 2T and 4T logic, crater filling, digital meters for current and voltage.
- Crater filling: the current falls at the end of the bead, so the crater does not crack and does not have to be corrected with a separate bead.
- Creep start of the wire: a calm ignition with no bounce of the torch and no heavy spatter at the start.
Technical data
| Brand | ESAB |
|---|---|
| Model | Origo MIG 5002cw |
| Adjustment technology | Chopper |
| Supply voltage | 400 V, 3 phases, 50 Hz |
| Welding current at a 60% duty cycle | 500 A |
| Welding current at a 100% duty cycle | 400 A |
| Welding current range | from 16 to 500 A |
| Protection class | IP23 |
| Control panel | Aristo U6, synergic control and pulse |
| Program memory | 10 channels |
| Cooling | liquid, built in cooler with a flow sensor |
| MMA electrodes | up to 6 mm and larger |
| Processes | synergic MIG/MAG, pulse, MMA, air carbon arc gouging |
What to watch out for
The range from 16 A lets you go down with the parameters on thinner parts, but this machine makes sense where you work at a high current on a regular basis. In pulse welding and on structures of changing geometry you will value that the arc holds in spite of changes of the distance from the torch to the material, and that TrueArcVoltage keeps the set voltage also with long cables, which in work to a WPS can be a condition of accepting the welds.
The supply is 400 V, 3 phases, 50 Hz, and class IP23 means a station under a roof. At currents above 400 A the cooling circuit runs all the time, so you check the fluid level, the tightness of the couplings and the state of the pump before the shift, the more so as the flow sensor will block welding if it fails. The torch and the cables have to be matched to 500 A, and for gouging you need a separate carbon torch and compressed air.
The Aristo U6 panel handles pulse and synergic control, but it has no double pulse, that function belongs to the higher U82 model. QSet sets the short arc by itself, so after a change of gas or position give it a few seconds of welding to match the dynamics. The set with the power source, the cooler and the separate feeder is heavy, so plan the transport with a trolley.
Before you buy, settle which feeder, torch and cable package belong to this piece, which set of rollers is fitted and whether you need digital meters at the station. When you work with flux cored wire and with electrodes of a large diameter, count also the power reserve in the installation, because a machine of this class can load the circuit more than a typical workshop MIG welder.
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