Welding Equipment Catalogue 2008-English 13.08
Transcript of Welding Equipment Catalogue 2008-English 13.08
Joining Solutions…
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Castolin Eutectic Welding Equipment
Catalogue
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CASTOLIN Eutectic
History of Castolin Eutectic 4
R&D / Technical Support 5
Welding Consumables Production 6
Training 7
Local Support 8 - 9
Professional Installation Products 10
Technical Data
Welding Processes Selection 11
MMA Welding Process
Manual Metal Arc Welding 13
UltraMax2 inverter (liftarc) 14
PowerMax inverter (liftarc) 14
XuperMax2 inverter (liftarc) 15
CastoMatec 305 (liftarc) 16
CastoMatec Xuper 455 16
CastoMatec Xuper 655 17
Accessories CastoMatec 17
TIG Welding Process
Tungsten Inert Gas Welding 19
CastoTIG 1501 DC 20
CastoTIG 1701 DC 20
CastoTIG 2201 DC and CastoTIG 3011/12 AC/DC 21
CastoTIG 1702 AC/DC and 2202 AC/DC 22
Electronic Wire Feeder 22
Accessories for CastoTIG 1701/2 2201/2 23
TIG torches selection 23 - 24
Plasma Cutting Process
Plasma Arc Cutting 25
AirJet 65 26
AirJet 105 26
Welcomecontents
MIG/MAG Welding Process
Metal Inert Gas/Metal Active Gas Welding 27
XuperMIG 2500 28
Accessories XuperMIG 2500 28
CastoMIG 160C 29
Accessories for CastoMIG 160C and 250C 29
CastoMIG 250 C and 350 C / 350DS 29
CastoMIG 400C / 400DS and 500C / 500DS 31
2 rolls system 32
4 rolls system / 2 rolls system 32
Accessories for CastoMIG 350C and DS 33
Accessories for CastoMIG 400/500 C and DS 33
Total Arc2 3000 (compact) (liftarc) 34
Total Arc2 4000 (separate wire feeder)(liftarc) 35
Total Arc2 5000 (separate wire feeder)(liftarc) 36
Accessories for Total Arc2 3000 / 4000 and 5000 36
Torches for MIG/MAG welding 37
MIG/MAG torches selection 37
PTA Process
Plasma Transferred Arc Process 39
Multi Plasma Module 40
EuTronic GAP 2001 DC basic 40
EuTronic GAP 2001 DC touch screen 41
EuTronic GAP 3001 DC 41
EuTronic GAP 3002 AC/DC 42
EuTronic GAP Automated Unit 42
Accessories for GAP 43-44
GAP torches 45
Special Products
IDweld 2501 46
GoodAire 1202 46
TeroMatec Wire Feeder 400 46
Addresses of Castolin Eutectic Companies in Europe 50
EutecTrode CastoTig Three phaseEnDOtec CastoMag Single phase
symbols used
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1906 Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre Wasserman. His stroke of genius : to discover a way of welding cast iron at low temperature. In the following years, this innovation was further developed for all industrial metals including aluminium alloys.
1940 Foundation of Eutectic Welding Alloys Corpo-ration in New York .
1952 Foundation of Castolin France.
1959 Foundation of Eutectic Japan Ltd.
1962 Foundation of Eutectic India Ltd.
1960’s International consolidation under Castolin Eutectic.
1970’s Creation of training centers for Maintenance & Repair technologies.
1978 Establishment of World Head Quarters in St-Sulpice, Switzerland.
2000 Merger with Messer Cutting & Welding and creation of the MEC Group - Messer Eutectic Castolin.
2005 Part of the Messer World.
2006 100 years.
Castolin Eutectichistory of castolin eutectic
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Castolin Eutectic employs many engineers and technicians solely focused on solving the technical problems of our customers. The main Castolin Eutectic research and development centre for welding products is in Dublin. This R&D centre is one of the most advanced welding technology laboratory in Europe.
This facility is equipped for in-depth studies of all types of industrial welding applications and problem solving solutions. Castolin Eutectic not only has G65, ICP or XRF units, automated Micro-Hardness machine, but also employs well trained and customer oriented technical team.
Our team has examined over 3500 metallurgical samples in the last 15 years, identifying the root causes of problems as well as recommending the required solutions.
As a Castolin Eutectic customer, you will receive the absolute best care and service to ensure the quality and efficiency of your production operations.
Ceil is certified to ISO 9001 : 2000 and has a TÜV approval for several electrodes and flux cored wires.
Castolin Eutecticr&d / technical support
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Castolin Eutecticwelding consumables production
Although, many companies have outsourced their production or are simply reselling electrodes and wires, Castolin Eutectic is dedicated to keeping the production in-house and in Europe. We are producing our welding consumables with new high-technology production equipment.
By developing and producing our own products, we are able to control the quality of every step in the production process. Anyway this is not enough for us; we are also strictly controlling and testing each batch. Castolin Eutectic uses only high quality raw materials, with high-technology equipment controlled by experts of the welding consumables production.
By having a wide range of products made in-house, Castolin Eutectic is able to offer excellent service, technical support and also to adapt the products to the needs of its customers.
As our production plant is located in Europe, we are able to deliver the products to any address in Europe within 24 hours if needed.
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Castolin Eutectictraining
At Castolin Eutectic, we offer a wide range of welding, brazing, and thermal spray training courses. These courses can be designed according to the needs of each customer. There are training sessions for managers, engineers and technicians.
Each course is composed of both theoretical as well as practical training. Castolin Eutectic can offer these courses in almost every European country. The courses are carried out in our own in-house training facilities, with qualified instructors or with our trainers at your location.
For more information about training, please contact your local Castolin Eutectic company. Contact information can be found in our Website : www.castolin.com.
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Castolin Eutectic has a presence in almost all European countries. With over 350 sales engineers travelling around Europe everyday, we are able to provide unbeatable service to our customers. We can literally be at 90 % of customers in Europe within 2 hours, this allows us to give unsurpassed service and support.
We supply all technical documentation and material safety data sheets in local languages. Our salesmen all live in their territories and speak local dialects and understand local cultures. We manage warehouses and keep stocks adapted to local requirements in every European country (including the new countries).
Our 350 sales engineers are supported by over 50 process and application experts. These experts are multi-lingual and communicate daily with our 4 production centers and research laboratories.
Castolin Eutecticlocal support
TeroLinkCastolin Eutectic employs over 2000 people worldwide. Our engineers are solving maintenance, repair and joining problems everyday. In order to transfer these solutions from one country to another, Castolin Eutectic has developed an application / solution database called TeroLink. This tool currently contains more than 8000 applications / solutions which allows us to demonstrate and offer tested and proven solutions to our customers.
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Castolin Eutecticprofessional installation products
Castolin Eutectic takes great care in complying with following standards and recommendations for key organisations like TÜV, DVGW, EDF, GDF and others.
Castolin Eutectic supports thousands of distributors and resellers by offering the full range of certified installation products and training.
For more information on how to become a distributor, or on the Castolin Eutectic products, please contact your local Castolin Eutectic company (see page 50)
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Technical Datawelding processes selection
CastoTig
Produc ts Process Vo
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(V
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(A)
Tech
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Sta
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Alu
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Ca
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U ltraMax 2 MMA 230 140 Inver ter
PowerMax MMA 230 150 Inver ter
XuperMax 2 MMA 380 250 Inver ter
CastoMatec 305 MMA 380 300 Thyristor
CastoMatec Xuper 455 MMA 380 450 Thyristor
CastoMatec Xuper 655 MMA 380 650 Thyristor
CastoTIG 1501 DC TIG 230 150 Inver ter
CastoTIG 1701 DC TIG 230 170 Inver ter
CastoTIG 1702 AC/DC TIG 230 170 Digital inver ter
CastoTIG 2201 DC TIG 230 220 Digital inver ter
CastoTIG 2202 AC/DC TIG 230 220 Digital inver ter
CastoTIG 3011/12 AC/DC TIG 380 300 Inver ter
AirJet 65 Plasma Cutting 380 65 Inver ter
AirJet 105 Plasma Cutting 380 105 Inver ter
XuperMIG 2500 MIG 400 150 Step switch
CastoMIG 160C MIG 230 160 Step switch
CastoMIG 250 C MIG 380 240 Step switch
CastoMIG 350 C, DS MIG 380 300 Step switch
CastoMIG 400 C, DS MIG 380 370 Step switch
CastoMIG 500 C, DS MIG 380 500 Step switch
TotalArc2 3000 MIG pulse 380 270 Inver ter
TotalArc 2 4000 MIG pulse 380 400 Inver ter
TotalArc 2 5000 MIG pulse 380 500 Inver ter
Base Metal EutecTrode CastoMag EnDOtec CastoTig
Carbon / al loy steels
Stainless steels
Aluminium / al loys
Titanium / al loys
Cast irons
Copper / al loys
Magnesium / al loys
Recommended variant Possible variant not recommended variant
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1) Consumable electrode - 2) Flux covering - 3) Core wire 4) Arc - 5) Evolved gas shield - 6) Weld pool - 7) Slag 8) Weld metal - 9) Parent metal
When an arc is struck between the flux coated electrode and the workpiece, both the core wire and the workpiece surface melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas and slag which protects the weld pool from the surrounding atmosphere. The slag will solidify and cool and must be chipped off the weld bead once the weld run is complete (or before the next weld pass is deposited).
Castolin Eutectic has developed the special EutecTrode alloy ranges of low heat input electrodes for industrial wearfacing, repair and joining applications.
MMA Welding Processmanual metal arc welding
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MMA Welding
PowerMax inverter (liftarc)
• Light, compact and robust• Voltage compensator• Spike protector• Fully portable
• For MMA and TIG welding with liftarc• Hot start, arc force control and anti stick function for perfect MMA welding• TIG welding with constant and pulsed current
Technical dataWelding amperage range 5 A - 140 A
35% Duty cycle amperage 140 A
100% Duty cycle amperage 100 A (at 40 °C)
Open circuit voltage 54 V
Power supply 230 V 50/60 Hz
Power at primary (100%) 4.6 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x W x H (mm) 310 x 120 x 215
Weight 4.3 Kg
UltraMax2 305650
Earth cable, 3m, 16mm2 305730
Welding cable, 4m, 16mm2 301054
OptionsWelding cable XuperFlex with ergonomic electrode holder 304335
Conversion cable for TIG-Torch 300826
Gas regulator 301669
TIG torches and wear parts see page 24
Technical dataWelding amperage range 10 A - 150 A
35% Duty cycle amperage 140 A
100%Duty cycle amperage 80 A (at 40 °C)
Open circuit voltage 92 V
Power supply 230 V 50/60 Hz
Power at primary (100%) 3.6 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x W x H (mm) 315 x 110 x 200
Weight 4.7 Kg
PowerMax 304300
Includes
Earth cable, 3m, 16mm2 300789
Welding cable, 4m, 16mm2 301094
OptionsWelding cable XuperFlex with ergonomic
electrode holder 304335
Conversion Cable for TIG-Torch 300826
Gas regulator 301669
TIG torches and wear parts see page 24
UltraMax2 inverter (liftarc)
• Variable characteristics allow welding of every kind of electrodes• Hot start, arc force control and anti stick function for perfect MMA welding• Fully portable
• Advanced inverter technology• Possiblity to weld cellulosic electrodes• Power generator compatible• TIG DC welding with liftarc
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MMA Welding
Technical dataWelding amperage range 10 A - 250 A
40% Duty cycle amperage 250 A
100% Duty cycle amperage 160 A (at 40°C)
Open circuit voltage 76 V
Power supply 3 x 400 V 50/60 Hz
Power at primary (100%) 12.1 kVA
Fuse rating 20 A
Protection index IP 23
Dimensions L x W x H (mm) 460 x 230 x 325
Weight 16 Kg
XuperMax2 305900
Includes
Earth cable with plug and workpiece clamp (4m, 35mm2) 303180
Welding cable wih plug and electrode holder (4m, 35mm2) 303181
AccessoriesRemote control RCT DC 300843
Remote control cable (0.75m) 302240
Remote control cable (5m) 302241
Remote control cable (10m) 302242
Remote control cable (15m) 302243
Argon gas regulator 301669
OptionsEarth cable with plug and workpiece clamp (6m, 50mm2) 303197
Welding cable wih plug and electrode holder (6m, 50mm2) 303119
XuperFlex welding cable (yellow, 4m, 35mm2)
with plug and ECO electrode holder 303184
XuperFlex welding cable (red, 6m, 50mm2)
with plug and ECO electrode holder 303192
TIG torches and wear parts see page 24
XuperMax2 inverter (liftarc)
• Suitable for 4mm electrodes• Remote current control available• TIG welding with liftarc ignition and constant or pulsed current• Light, compact and robust design for industrial use• Hot start, arc force control and anti stick function for perfect MMA welding
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MMA Welding
CastoMatec 305 (liftarc)Technical dataWelding amperage range 5 A - 300 A
35% Duty cycle amperage 300 A
60% Duty cycle amperage 230 A
100% Duty cycle amperage 180 A
Open circuit voltage 75 V
Voltage at striking 55 V
Power supply 3 x 230V /400V 50/60 Hz
Power at primary (100%) 8.9 kVA
Fuse rating 35A/230V - 20A/400V
Protection index IP 23
Dimensions L x W x H (mm) 675 x 500 x 450
Weight 95 Kg
CastoMatec 305 303115
With 3m main cable and CEE 32A plug
AccessoriesGasregulator 301633
Options Digital ammeter 303076
Single lug lifting bar 303080
TIG torches and wear parts see page 24
• 300 amps @ 35% duty cycle• Thyristor controlled DC transformer rectifier unit• Trolley mounted• Robust design for heavy industrial use
• Remote control unit FR3-1 optional• Welding cables extra• TIG welding with liftarc possible
Technical dataWelding amperage range 5 A - 450 A
35% Duty cycle amperage 450 A
60% Duty cycle amperage 340 A
100% Duty cycle amperage 260A
Open circuit voltage 75 V
Power supply 3 x 230V / 400V / 500 V / 50/60 Hz
Power at primary (100%) 18.5 kVA
Fuse rating 80A/230V -50A/400V
Protection index IP 23
Dimensions L x W x H (mm) 950 x 740 x 670
Weight 240 Kg
CastoMatec Xuper 455 302790
With 3m main cable and CEE 63A plug
OptionsDigital ammeter 302792
Accessories for air-carbon arc gouging 303149
• 450 amps @ 35% duty cycle• Thyristor controlled DC transformer rectifier unit• Trolley mounted• Robust design for heavy industrial use
• Remote control unit FR3-1 optional• Welding cables extra• Suitable for welding and gouging applications
CastoMatec Xuper 455
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MMA Welding
CastoMatec Xuper 655
Technical dataWelding amperage range 5 A - 650 A
35% Duty cycle amperage 650 A
60% Duty cycle amperage 490 A
100% Duty cycle amperage 380 A
Open circuit voltage 75 V
Power supply 3 x 230V /400V / 500 V / 50/60 Hz
Power at primary (100%) 26 kVA
Fuse rating 100A/230V -63A/400V
Protection index IP 23
Dimensions L x W x H (mm) 950 x 740 x 670
Weight 284 Kg
CastoMatec Xuper 655 303170
With 3m main cable and CEE 63A plug
OptionsDigital ammeter 302792
Accessories for air-carbon arc gouging 303149
• 650 amps @ 35% duty cycle• Thyristor controlled DC transformer rectifier unit• Trolley mounted• Robust design for heavy industrial use• Remote control unit FR3-1 optional• Welding cables extra• Suitable for welding and gouging applications
Accessories CastoMatec
OptionsWelding cable XuperFlex with with plug and Eco electrode holder (red, 4 m, 50 mm2) 303192
Welding cable, 6 m, 50 mm2, with plug and electrode holder 400 A 303119
Earth cable, 6 m, 50 mm2, with plug and 400 A electrode holder 303197
Earth cable, 6 m, 50 mm2, with plug 400 A workpiece clamp 303118
Remote control unit FR 3-1 for current setting 303075
Remote control cable for Remote control unit FR 3-1 (10 m) 303077
Remote control cable for Remote control unit FR 3-1 (20m) 303078
Remote control cable for Remote control unit FR 3-1 (30m) 303079
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1) Gas nozzle - 2) Gas shielding - 3) Filler rod - 4) Weld pool - 5) Weld bead - 6) Parent metal
TIG Welding Processtungsten inert gas welding
In the TIG process the arc is formed between a tungsten electrode and the workpiece in an inert atmosphere of argon or helium. The small intense arc provided by the electrode is ideal for high quality and precision welding.
The tungsten electrode is not consumed during welding. The heat of the arc melts the base metal and a separate filler rod can be added into the weld pool if required.
Castolin Eutectic has developed the special CastoTig alloy range for industrial wearfacing, repair and joining applications.
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TIG Welding DC
CastoTIG 1501 DC
Technical dataWelding amperage range 5 A - 150 A (TIG) –140 A (MMA)
35% Duty cycle amperage 150 A
100% Duty cycle amperage 100 A
Open circuit voltage 54 V
Power supply 230 V single-phase 50/60 Hz
Power at primary (100%) 5.9 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x W x H (mm) 360 x 120 x 215
Weight 5.7 Kg
CastoTIG 1501 DC 305300
OptionsWelding cable, 4m 301094
Earth Cable, 3m 300789
Gas regulator 301669
TIG torches and wear parts see page 24
• Single phase 230 volts TIG & MMA inverter• DC TIG with HF or liftarc• Microprocessor controlled welding cycle• 150 amps DC output• DC- TIG Pulse mode
CastoTIG 1701 DC
Technical dataWelding amperage range 3 - 170 A (TIG) - 140 A (MMA)
35% Duty cycle amperage 170 A
100% Duty cycle amperage 110 A
Open circuit voltage 92 V
Power supply 230 V single-phase 50/60Hz
Power at primary (100%) 3.3 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x W x H (mm) 485 x 175 x 345
Weight 10 Kg
CastoTIG 1701 DC 304400
OptionsWelding cable, 4m 303181
Earth cable, 3m, 35mm2 303180
Gas regulator 301669
TIG torches and wear parts see page 24
• Single phase 230 volts TIG & MMA Digital inverter• DC TIG with HF or liftarc• Microprocessor controlled welding cycle• 170 amps DC output• Remote control optional• Separate pulse unit available
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TIG Welding DC
CastoTIG 2201 DC
Technical dataWelding amperage range (TIG) 3 A-220 A
Electrode 10 A-180 A
Welding amperage
35% Duty cycle 220 A
60% Duty cycle 170 A
100% Duty cycle 140 A
Open circuit voltage 84 V
Power supply 1 x 230 V / 50/60 Hz
Power at primary (100%) 2.7 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x W x H (mm) 500 x 175 x 410
Weight 16.8 kg
CastoTIG 2201 DC 304901
OptionsWatercooling 2200 304960
TIG torches and wear parts see page 24
• Single phase 230 volts TIG & MMA Digital inverter• DC TIG with HF or Liftarc• Microprocessor controlled welding cycle• 220 amp DC output• Remote control optional• DC - pulse mode
CastoTIG 3011 DC / 3012 AC/DCTechnical dataWelding amperage range 3 - 300 A (TIG) 10 - 300 A (MMA)
Duty cycle 45% 300 A
Duty cycle 100% 230 A
Open circuit voltage 85 V
Power supply 3 X 400 V +/- 15%
Power at primary (100%) 6.1 kVA
Fuse rating 16 A
Protection index IP 23
Dimensions L x l x H (mm) 590 x 245 x 450
Weight CastoTIG 3011 DC 23 kg
Weight CastoTIG 3012 AC/DC 27 kg
CastoTIG 3011 DC 307500
CastoTIG 3012 AC/DC 307600
OptionsRemote control RC2 300255
Trolley 307615
cooling 3011/3012 307580
• Powerful 300 Amps TIG equipment for only 23 et 27 kg• New technology with highest precision and efficiency• Friendly user• Fully digitally controlled
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TIG Welding AC/DC
Technical data 1702 AC/DC 2202 AC/DCWelding amperage range (TIG) 3 A - 170 A 3 A-220A
Electrode 10 A-140 A 10 A-180
Welding amperage
30% Duty cycle 170 A 220 A
60% Duty cycle 120 A 160 A
100% Duty cycle 90 A 130 A
Open circuit voltage 90 V 93 V
Power supply 1 x 230 V / 50/60 Hz 1 x 230 V / 50/60 Hz
Power at primary (100%) 3.0 kVA 3.0 kVA
Fuse rating 16 A 16 A
Protection index IP 23 IP 23
Dimensions L x W x H (mm) 500 x 175 x 410 500 x 175 x 410
Weight 15 kg 17.3 kg
CastoTIG 1702 AC/DCand 2202 AC/DC
304900 304902
OptionsWatercooling 2200 304960
TIG torches and wear parts see page 24
• Single phase 230 volts TIG & MMA Digital inverter• AC/DC TIG with HF or Liftarc• Microprocessor controlled welding cycle• 170/220 amp AC/DC output• Remote control optional• Pulse mode
CastoTIG 1702 AC/DC and 2202 AC/DC
Electronic Wire FeederPower supply 230VAC
Max. power consumption 370VA
Max.wire speed 10m/min
Suitable wire diameters 0.8 – 3.2 mm
Weight 30 Kg
• Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder for 16 Kg wire coils. • Special designed pressure arms care for a smooth and reproducible pressure of the wire onto the feeder rolls within the drive.• Electonically motor controller for the four roll wire feeder. Functions: forward/backward movement, wire inching, wire feedback, pulse functions, control signals for fault indication. • Buttons for: wire inching, forward/backward movement, speed and pulse adjustment.
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TIG Welding Accessories and Torches
Gas cooled Torches with manuel gas valve 4 m Article 8 m ArticleG 140 RA 110 A = / 95 A ~ at 60% Duty cycle 301715 301719
G 220 RA 220 A = / 200 A ~ at 40% Duty cycle 301238 301241
Gas cooled TorchesG 90 UD/D 90 A = / 50 A ~ at 35% Duty cycle 301279 301282
G 160 160 A = / 140 A ~ at 40% Duty cycle 304120 304121
G 220 UD/D 220 A = / 200 A ~ at 40% Duty cycle 301153 301156
G221 U/ D 200 A = / 180 A ~ at 35% Duty cycle 305000 305001
Water cooled TorchesW 201 UD/D 220 A = / 200 A ~ at 100% Duty cycle 304986 304990
W 400 B1/UD 400 A = / 360 A ~ at 60% Duty cycle 500264 500265
Accessories for CastoTIG 1701/2 2201/2
Options 1701DC 1702AC/DC 2201DC 2202AC/DCEarth cable (4m, 35mm2) 303180 303180 303180 303180
Remote control RCT DC 300843 300255 300255 300255
Remote control RCT AC - 300256 - 300256
Remote control RCT P 300845 - - -
Remote control unit RCT F 300846 304973 304973 304973
Cooling - - 304960 304960
Trolley with gas cylinder 304440 304440 304440 304440
TIG torches selection
G 140 RA G 220 UD/D
G 221 UD/D W 400 B1/UD
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TIG Welding torches
TIG torches selection
ESC Equipment
TIG welding torches 4m 8m Ult
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G90 U D/D 301279 301282
G140 RA 301715 301719
G160 304120 304121
G220 RA 301238 301241
G220 U D/D 301238 301156
G221 U D/D 305000 305001
W201 U D/D 305000 304990 Cooling 2200 Cooling 2200
W400 B1/U D 500264 500265 Cooling 2200 Cooling 2200
Recommended variant Possible variant Not recommended variant
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Plasma arc cutting has always been seen as an alternative to the oxy-fuel process. However, the important difference between the two processes is that while the oxygen-fuel process oxidises the metal and the heat from the exothermic reaction melts the metal, the plasma process operates by using the heat from the arc to melt the metal. The ability to melt the metal without oxidation is essential when cutting metals, such as stainless steel, which form high temperature oxides.
Plasma is an effective means of cutting thin and thick materials alike. Handheld torches can usually cut up to 48 mm thick steel plate, and more powerful computer-controlled torches can pierce and cut steel up to 300 mm thickness.
plasma arc cuttingPlasma Cutting Process
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Plasma Cutting
AirJet 65
Technical DataCutting thickness (mild steel) capacity about 10 mm
Repair 15 mm
Severing 20 mm
Amperage range 20 - 65 A
Open circuit voltage 540 V
Power supply 3 x 400 V
Max. input power 9 kVA
Protection index IP 23
Compressed Air required 5 bar
Max. air consumption 130 l/min
Weight 18 Kg
Dimensions L x W x H (mm) 586 x 215 x 385
AirJet 65 306600
• Precision cut 10mm• Severance cut 20mm• Cutting only with the T70 torch• Torch standard cable length 6 meters (12 meter available on request)• Air tunnel technology to protect electronic parts against dusty cooling air flows• Portable 18 kg
AirJet 105
Technical DataCutting thickness (mild steel) capacity about 20 mm
Repair 30 mm
Severing 40 mm
Amperage range 20 - 105 A
Open circuit voltage 540 V
Power supply 3 x 400 V
Max. input power 15 kVA
Protection index IP 23
Compressed Air required 5 bar
Max. air consumption 180 l/min
Weight 28 Kg
Dimensions L x W x H (mm) 711 x 275 x 500
AirJet 105 306500
• Precision cut 20mm carbon steel• Severance cut 40mm carbon steel• Cutting and gouging with the T100 torch• Torch standard cable length 6 meters (12 meters available on request)• T100M torch for cutting machine mounting• Air tunnel technology to protect electronic parts against dusty cooling air flows• Portable 28 kg
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1) Gas nozzle - 2) Contact tube - 3) solid/cored wire 4) Gas shield - 5) Arc - 6) Weld pool - 7) Weld metal8) Parent metal
MIG is similar to MMA in that heat is produced by forming an arc between a metal electrode and the workpiece; the electrode melts to form the bead. The main differences are that the metal electrode is a small diameter wire fed from a spool and an externally supplied shielding gas is necessary. As the wire is continuously fed, the process is often referred to as semi-automatic welding.
The pulse mode was developed as a means of stabilizing the open arc at low current values below the threshold level, to avoid short-circuiting and spatter. Metal transfer is achieved by applying pulses of current, each pulse having sufficient force to detach a droplet.
Castolin Eutectic has developed the special EnDOtec (cored wire) and CastoMag (solid wire) alloy ranges for industrial wearfacing, repair and joining applications.
MIG/MAG Welding Process metal inert gas/metal active gas welding
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MIG/MAG Welding
XuperMIG 2500
• MMA, TIG,MIG-MAG welding and MIG brazing• User friendly • Synergic programs for most important wires• Portable multifunctional welding source• Step less welding current control• Step less adjustable choke• Adjustable down slope and crater fill current• Hot start, arc force control and anti-stick fundtion for perfect welding
Technical DataWelding amperage range 5 – 250 A
MIG/MAG duty cycle 30%: 250 A / 26.5 V
100%: 140 A / 21 V
MMA duty cycle 40%: 200 A / 28 V
100%: 130 A / 25.2 V
TIG duty cycle 40%: 200 A / 18 V
100%: 130 A / 12.2 V
Fuse rating 16 A
Power supply 3 X 400 V + 15% 50-60 Hz
Open circuit voltage (MIG/MAG, MMA, TIG) 9 V / 76 V / 9 V
Protection Index IP 23
Insulation class H
Cooling AF
Weight 22 Kg
Dimensions L x W x H (mm) 670 x 310 x 490 mm
MIG/MAG torches and wear parts see page 37
• TIG torches will be changed due to the plug
Accessories for XuperMIG 2500
XuperMIG 25oo 307200
CastoPlus Torch 250G/3m 303802
CastoPlus Torch 250G/4m 303803
Torch TIG WT26 4m XuperMIG 307151
Torch TIG WT26 8m XuperMIG 307152
Earth cable 3,5m 35mm2 301061
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29
MIG/MAG Welding
CastoMIG 160C
Technical dataWelding amperage range 30 - 160 A
30% Duty cycle amperage 100 A
100% Duty cycle amperage 60 A
Operating voltage 15.5 – 21.5 V
Open circuit voltage 37 V
Number of arc voltage positions 6
Power supply 1 x 230 V ± 10% 50/60 H
Power at primary (100%) 2.7 kVA /100 %
Fuse rating 16 A
Protection index IP 21
Dimensions L x W x H (mm) 785 x 490 x 710
Weight 61 Kg
CastoMIG 160C 304033
Includes
Earth cable, 3m, 35mm2
with plug and workpiece clamp 301061
Shielding gas hose, 1.5m 300693
MIG/MAG torches and wear parts see page 37
• Step-switched MIG/MAG machine • Robust construction, with outstanding mobility and stability ideal for workshop environments• Compact design featuring a 2-roll type integrated feeder, and a rear platform for gas cylinder • Pull-off drawer for practical storage of small tooling and wear parts for the torch• Easy wire loading thanks to wide access to the mechanical compartment
Accessories for CastoMIG 160C and 250C
Conversion kit socket for gas preheater, 230V / 2A 303426
Argon/CO2 gas regulator 301669
Adaptor diam.185mm 300005
Earth cable, 3m, 35mm2
with plug and workpiece clamp 301061
Wire feeding rollsDrive roll with trapezoidal groove for solid wires diam.0.8mm 303433
Drive roll with trapezoidal groove for solid wires diam.1mm 303434
Pressure rollsDrive roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm 303467
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm 302762
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm 303468
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm 303763
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm 303469
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm 303755
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MIG/MAG Welding
CastoMIG 250C and 350C / 350DS
• Compact MIG/MAG welding unit for gas-cooled torches• Field-proven technology for excellent welding results• 2-step and 4-step control cycle, spot and intermittent welding• Excellent price-to-performance ratio• CastoMIG 350 C/DS available with 2-rolls or 4-rolls feeder, with or without digital displays
Technical data 250C 350C / 350DSWelding amperage range 25 - 240 A 20 -340 A (350C) / 20 -300 A (350DS)
30% Duty cycle amperage 240 A 300A
60% Duty cycle amperage - 210 A (240 A at 25 °C)
100% Duty cycle amperage 130 A 140 A
Operating voltage a15.8 - 26 V 15 - 31 V
Open circuit voltage 37 V 43 V
Number of arc voltage positions 10 15
Power supply 3 x 400/3 x 230 V ± 15% 50/60 Hz 3 x 400/3 x 230 V ± 15% 50/60 Hz
Power at primary (100%) 3.7 kVA /100 % 4.1 kVA /100 % Duty cycle
Fuse rating 10 AT/400 V / 20 AT/230 V 20 AT/400 V / 25 AT /230 V
Protection index IP 21 IP 21
Dimensions L x W x H (mm) 785 x 490 x 710 785 x 490 x 810
Weight 74 Kg 101 Kg (350C) / 97 KG (350DS)
CastoMIGCastoMIG 250C with four roll drive,
earth cable and gas hose 303400 -
CastoMIG 350C with two roll drive,
earth cable and gas hose: - 303400 (350C) / 303404 (350DS)
CastoMIG 350C with four roll drive,
earth cable and gas hose - 303402 (350C) / 303405 (350DS)
CastoMIG 350 DS
with earth cable and gas hose: 303403 (350DS)
IncludesEarth cable, 3m, 35mm2
with plug and workpiece clamp 301061 -
Earth cable, 4m, 50mm2
with plug and workpiece clamp - 303483
Shielding gas hose, 1.5m 300693 300693 (350C)
Options/Accessories for CastoMIG 350C/DSHolder for DS I - 303436 (350DS)
Wirefeeder CastoMIG DS I 2-Roll - 303404 (350DS)
MIG/MAG torches and wear parts see page 37Conversion kit 4 rolls feeder for CastoMIG 350 C/DS more see page 32
CastoMIG 250C CastoMIG 350C CastoMIG 350DSseparate Wire Feeder
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MIG/MAG Welding
CastoMIG 400C / 400DS and 500C / 500DS
Technical data 400C / 400DS 500C / 500DSWelding amperage range 30 - 370 A 35 - 500 A
30% Duty cycle amperage 370 A 500 A
60% Duty cycle amperage 280 A (300 A at 25°C) 360 A (410 A at 25°C)
100% Duty cycle amperage 220 A (235 A at 25°C) 280 A (315 A at 25°C)
Operating voltage 15.5 - 32.5 V 15.8 - 39 V
Open circuit voltage 43 V 54 V
Number of arc voltage positions 21 28
Power supply 3 x 400/ 3 x 230 V ± 15% 50/60 Hz 3 x 400/ 3 x 230 V ± 15% 50/60 Hz
Power at primary (100%) 7.6 kVA / 100% 10.2 kVA / 100%
Fuse rating 25 AT/ 400 V / 35 AT / 230 V 35 AT/ 400 V / 63 AT / 230 V
Protection index IP 23 IP 23
Dimensions L x W x H (mm) 950 x 465 x 895 (C) / 950 x 465 x 785 (DS) 950 x 465 x 895 (C) / 950 x 465 x 785 (DS)
Weight 137 Kg (400C) / 129 Kg (400DS) 156 Kg (500C) / 148 Kg (500DS)
CastoMig 303406 (400C) / 303408 (400DS) 303410 (500C) / 303412 (500DS)
With switch synergic program CMP 45 303407 (400C) / 303409 (400DS) 303411 (500C) / 303413 (500DS)
IncludesEarth cable, 4m, 50mm2
with plug and workpiece clamp 303483 -
Earth cable, 4m, 70mm2
with plug and workpiece clamp - 303484
Shielding gas hose, 1.5m 300693 (400C) 300693 (500C)
Options / AccessoriesCooling CMC 47, 230V / 50Hz 303415
MIG/MAG torches and wear parts see page 37
• Powerful MIG/MAG welding plants for industrial use• Field-proven technology for excellent welding results• Extremely easy adjustment of parameters with the program unit CMP 45 (option)• 2-step and 4-step control cycle, spot and intermittent welding• For gas or water-cooled torches
CastoMIG 400CCompact
CastoMIG 400DS
separate Wire Feeder
CastoMIG 500CCompact
CastoMIG 500DS
separate Wire Feeder
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32
MIG/MAG Welding
2 Rolls system
4 Rolls system / 2 Rolls system
Wire Diameter
Drive roll with
groove
Feedroll with
groove
Pressure roll
smoothPCS Article PCS Article PCS Article
Ø 0.8 1 303467 1 302762 - -
Ø 1.0 1 303468 1 302763 - -
Ø 1.2 1 303469 1 302755 - -
Ø 1.6 1 303470 1 302764 - -Semi circular groove smooth steel teeth
Aluminium + cored wire
Ø 0.8 1 303433 * - - 1 302852 *
Ø 1.0 1 303434 * - - 1 302852 *
Ø 1.2 1 302695 - - 1 302852 *
Ø 1.6 1 303435 - - 1 302852 *Trapezoidal groove steel teethFe + CrNi * Rolls without teeth
1) Drive roll with groove2) Feedroll with groove3) Pressure roll smooth
Wire Diameter
Feedroll with groo-
ve
Pressure roll
smoothDrive gear
PCS Article PCS Article PCS ArticleØ 0.8 4 2 302762 - - 1 302756
Ø 1.0 4 2 302763 - - 1 302756
Ø 1.2 4 2 302755 - - 1 302756
Ø 1.6 4 2 302764 - - 1 302756
Ø 0.8 2 1 302765 2 1 302852 * 1 302756
Ø 1.0 2 1 302766 2 1 302852 * 1 302756
Ø 1.2 2 1 302767 2 1 302852 * 1 302756
Ø 1.6 2 1 302768 2 1 302852 * 1 302756
* Rolls without teeth
2) Feedroll with groove3) Pressure roll smooth4) Drive gear
Ø 1.2 4 2 302769 - - 1 302756
Ø 1.6 4 2 302770 - - 1 302756
Ø 2.0 4 2 302771 - - 1 302756
Ø 2.4 4 2 302772 - - 1 302756
Ø 2.8 4 2 302773 - - 1 302756Semi circular groove knurled steel teeth
Cored wire
Semi circular groove smooth steel teethAluminium + cored wire
Trapezoidal groove steel teethFe + CrNi
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MIG/MAG Welding
Accessories for CastoMIG 350C and DS
Conversion kit A/V - digital display 303425
Conversion kit socket for gas preheater, 230V / 2A 303426
Conversion kit soft start speed for 350C 303427
Conversion kit soft start speed for 350DS 303428
Trolley for DSI and DSII 303432
Holder for DSI 303436
Connexion cable assembly for DSI, 5m/10m 30342(3/4)
Argon/CO2 pressure reducer 301669
Adaptor diam.185mm 300005
Earth cable, 4m, 50mm2
wih plug and workpiece clamp 301483
Drive roll with trapezoidal groove for solid wires diam.0.8mm 303433
Drive roll with trapezoidal groove for solid wires diam.1mm 303434
Drive roll with trapezoidal groove for solid wires diam.1.2mm 302695
Press roll 302852
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm 303467
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm 302762
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm 303468
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm 303763
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm 303469
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm 303755
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.6mm 303470
Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.6mm 303764
Accessories for CastoMIG 400/500 C and DS
Cooling CMC 47, 230V / 50Hz 303415
Conversion kit 4-roll feeder 303421
Feed roll, with trapezoidal groove for solid wire diam.1mm 302766
Feed roll, with trapezoidal groove for solid wire diam.1.2mm 302767
Pressure roll 302852
Connection cable assembly for DSII, gas cooled, 5m/10m 30341(7/8)
Connection cable assembly for DSII, water cooled, 5m/10m 3034(19/20)
Conversion kit push/pull for torch MSG816 303429
Conversion kit socket for gas preheater, 230V / 2A 303426
Conversion kit Lifting eyes 303431
Conversion kit program unit CMP45 303416
Conversion kit Control socket 9 poles 303549
Trolley for DSI and DSII 303432
Holder for DSII 303422
Cooling CMC 46, 230V, 50/60Hz, with rotating pump 303430
Argon/CO2 gas regulator 301669
Adaptor diam.185mm 300005
Earth cable, 4m, 50mm2 wih plug and workpiece clamp 301483
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34
MIG pulse Welding
Total Arc2 3000
Technical dataWelding amperage range 3 - 270 A
40% Duty cycle amperage 270 A
60% Duty cycle amperage 210 A (270 A at 25°C)
100% Duty cycle amperage 170 A (210 A at 25°C)
Operating voltage 14.2 - 27.5 V
Open circuit voltage 50 V
Power supply 3 x 400/ 50/60 Hz
Power at primary (100%) 4.5 kVA / 100%
Fuse rating 16 AT/ 400 V
Protection index IP 23
Dimensions L x W x H (mm) 940 x 580 x 900
Weight 71 Kg
Total Arc2 3000 303650
Digital Dual voltage 303651
IncludesPrograms display chart 303713
Shielding gas hose, 1.5m 300693
OptionsEarth cable, 3 m, 35 mm2
with plug and workpiece clamp 301061
Earth cable, 4 m, 70 mm2
with plug and workpiece clamp 303484
MIG/MAG torches and wear parts see page 37
• Digital controlled inverter• Transistor controlled welding rectifier• Programmed and manual MIG/MAG• Standard & pulsed MIG/MAG welding• 3 phase 400 volts input• 270 amp output• Integrated water cooler• 73 welding programmes• 50 job settings storable• 2 step – 4 step special 4 step• Up down control on torch during use • Dual pulse programme available• Remote controls available• MMA & TIG available as standard• 4 roll wire feed standard
(compact) (liftarc)
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35
MIG pulse Welding
Total Arc2 4000 (separate wire feeder) (liftarc)
Technical dataWelding amperage range 3 - 400 A
40% Duty cycle amperage 400 A
60% Duty cycle amperage 365 A (400 A at 25°C)
100% Duty cycle amperage 320 A (365 A at 25°C)
Operating voltage 14.2 - 34.0 V
Open circuit voltage 70 V
Power supply 3 x 400/ 50/60 Hz
Power at primary (100%) 12.7 kVA / 100%
Fuse rating 35 AT/ 400 V
Protection index IP 23
Dimensions L x W x H (mm) 910 x 580 x 900
Weight 75 Kg
Total Arc2 4000 303740
Digital Dual voltage 303741
IncludesOperating manual&spare parts list 303741
Programs display chart 303741
Shielding gas hose, 1.5m 303741
Options / AccessoriesWire feeder DS3 303733
Earth cable, 3 m, 35 mm2
with plug and workpiece clamp 301061
Earth cable, 4 m, 70 mm2
with plug and workpiece clamp 303484
MIG/MAG torches and wear parts see page 37
• Digital controlled inverter• Transistor controlled welding rectifier• Programmed and manual MIG/MAG• Standard & pulsed MIG/MAG welding• 3 phase 400 volts input• 400 amp output• Integrated water cooler• 86 welding programmes• 50 job settings storable• 2 step – 4 step special 4 step• Up down control on torch when using CastoPlus 500W UD• Dual pulse programme available• Remote controls available• MMA & TIG available as standard
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36
MIG pulse Welding
Total Arc2 5000 (separate wire feeder) (liftarc)
Technical dataWelding amperage range 3 - 500 A
40% Duty cycle amperage 500 A
60% Duty cycle amperage 450 A (500 A at 25°C)
100% Duty cycle amperage 360 A (450 A at 25°C)
Operating voltage 14.2 - 39.0 V
Open circuit voltage 70 V
Power supply 3 x 400/ 50/60 Hz
Power at primary (100%) 15.1 kVA / 100%
Fuse rating 35 AT/ 400 V
Protection index IP 23
Dimensions L x W x H (mm) 910 x 580 x 900
Weight 75 Kg
Total Arc2 5000 303750
Digital Dual voltage 303751
Options / AccessoriesHolder for DS III 303734
Wirefeeder CastoMIG DS III 303733
Connection cable assembly, 5 m 303736
Earthing cable, 6 m, 70 mm2 303484
MIG/MAG torches and wear parts see page 37
• Digital controlled inverter• Transistor controlled welding rectifier• Programmed and manual MIG/MAG• Standard & pulsed MIG/MAG welding• 3 phase 400 volts input• 500 amp output• Integrated water cooler• 86 welding programs• 50 job settings storable• 2 step – 4 step special 4 step• Up down control on torch when using CastoPlus 500W UD• Dual pulse programme available• Remote controls available• MMA & TIG available as standard
Accessories for Total Arc2 3000 / 4000 and 500O
Remote control unit RC 2 300255
Remote control unit RC4 300256
Remote control cable, 0.75m/5m/10m/15m/20m 30224(1/2/3/4)
Argon/CO2 gas regulator 301669
Trolley for DSIII 303432
Holder for DSIII 303734
Interconnection cable assembly 1.5/5/10/15/20 3037 (35/36/37/38/39)
Torch balancing boom XUPERlight 303742
Installation set for push/pull torch 303718
Interface AUT 2 for automatised applications 303744
External start button, with plug and 5m cable 302652
Interface for connecting TotalArc with a personal computer 303767
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37
MIG pulse Welding
MIG/MAG Torches Selection
Torches for MIG/MAG weldingGas cooled torches 3 m 4 m 5 mCastoPlus 150 G 150 A = at 60 % Duty cycle 30380 0 30380 1 -
CastoPlus 250 G 200 A = at 60 % Duty cycle 30380 2 30380 3 -
CastoPlus 360 G 320 A = at 60 % Duty cycle 30380 4 30380 5 30380 6
Water cooled torchesCastoPlus 300 W 270 A = at 100 % Duty cycle 30380 7 30380 8 30380 9
CastoPlus 500 W 450 A = at 100 % Duty cycle 30381 0 30381 1 30381 2
CastoPlus 500 W U/D 450 A = at 100 % Duty cycle 30381 3 30381 4 30381 5
CastoPlus 601 W 550 A = at 100 % Duty cycle 30394 0 30394 1 30394 2
Water cooled torches for heavy duty EnDotec applications 1.5 m 3 m 5 mMSG 400 FD 400 A = at 100 % Duty cycle - 302474 -
Water cooled machine torchesMSG 350 MB 350 A = at 100 % Duty cycle 302254 - -
MSG 500 MB 500 A = at 100 % Duty cycle - 302282 302288
Water Cooled push pull torchesMSG 816(A) - 302439 302442
Equipment
MIG/MAG welding torches 3m/4m/5m C
ast
oM
IG 1
60
C
Ca
sto
MIG
25
0C
Ca
sto
MIG
35
0 C
/D
S
Ca
sto
MIG
4
00
/50
0 C
/DS
Ca
sto
MIG
4
00
/50
0 C
/DS
/W
***
Xu
pe
rMig
25
00
Tota
lArc
2 3
00
0/4
00
0/5
00
0CastoPlus 150G 303800/1
CastoPlus 250G 303802/3
CastoPlus 360G 303804/5/6
CastoPlus 300W 303807/8/9
CastoPlus 500W 303810/1/2
CastoPlus 500W U/D 303813/4/5
CastoPlus 601W 303940/1/2
MSG 400 FD 302474
MSG 350MB 1,5m 302254
MSG 500MB 302282/302288
MSG 816(A) 5m 302439/302442with push pul l card
with push pul l card
Id-Weld torch gas cooled 300587
Id-Weld torch water cooled 300588
Recommended variant Possible variant not recommended variant
*** with watercool ing
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1) Cathode holding device - 2) Plasma gas - 3) Cathode 4) Cooling water - 5) Shielding gas - 6) Feeding gas and powder - 7) Welding direction - 8) Ignition - 9) Double power supply
PTA Processplasma transferred arc process
The Eutronic© GAP is the Castolin Eutectic Plasma Transferred Arc (PTA) process. GAP is ideal for coating and joining operations. In the PTA process, the plasma is focused while forced through the heat resistant anode, causing a considerable increase of the arc density, energy and temperature. The welding filler alloy, in micro-atomized powder or cold wire form, is conveyed into the plasma arc column where a shielding gas protects the wed pool from the atmosphere.
Castolin Eutectic has developed special powders for GAP applications.
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Plasma Transferred Arc & Powder Coating
Multi Plasma ModuleTechnical DataSupply voltage 230V +N 50/60Hz
Max power consumption 0.9kVA
Welding current TIG-inverter (60% ED) 270A
Welding current TIG-inverter (100% ED) 220A
Open-circuit voltage 110 V DC
Adjustment range pilot current 5 - 20A
Protection type IP 23
Dimensions L x W x H (mm) 565 x 265 x 460
Weight 29 kg
Multi plasma module 1007495
OptionsInterconnecting cable PMB/Z-2m for
CastoTig 1601DC / 1701DC / 1702AC/DC
2201 DC / 2202 AC/DC 1002713
Interconnecting cable PMB/Z-2m for 3002AC/DC 1002711
Al-Module for Multi Plasma Module 1004439
WPL manual torch E12N, 4m Water-cooled,
for plasma welding 400900
Liner unit for WFE, 3m 260422
• Expandable modular design• An affordable start in plasma welding• Separate power source required, see CastoTIG power source
• Extension for existing TIG sources• All purpose plasma welding unit• Extremely versatile due to light weight design• Equipped for micro-plasma welding• Works with WFE wire feeder
EuTronic GAP 2001 DC basic
Technical dataVoltage supply 3x400 + N ± 10%
Power supply 5X16A CEE plug
Supply frequency 50/60 Hz
Welding current(100%ED) 160A
Adjustment range 1.0 - 160A
Max power consumption 16 KVA
Open circuit V main inverter 90 V
Open circuit V pilot inverter 110 V
Pilot current(100%ED) 20A
Adjustment range pilot current 5 - 20A
Protection index IP 23
Dimensions L x W x H (mm) 815x455x635
Weight 63 Kg
EuTronic GAP 2001 DC basic 260234
with powder and Cold Wire settings 260063
Accessories for GAP see page 42
• Plasma welding from 1A to 160A• Manual settings• Works with WF cold wire feeder• Hand held torch or machine torches available
• 50 Job settings storable• TIG welding & cold wire TIG welding• Trolley mounting facility
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41
Plasma Transferred Arc & Powder Coating
EuTronic GAP 2001 DC touch screen
Technical dataVoltage supply 3x400 + N ± 10%
Power supply 5X16A CEE plug
Supply frequency 50/60 Hz
Welding current(100%ED) 160A
Adjustment range 1.0 - 160A
Max power consumption 16 KVA
Open circuit V main inverter 90 V
Open circuit V pilot inverter 100 V
Pilot current (100%ED) 10A
Adjustment range pilot current 0.5 - 10A
Protection index IP 23
Dimensions L x W x H (mm) 815x455x635
Weight 70 Kg
EuTronic GAP 2001 DC touch screen 260233
OptionLike basic with powder and Cold Wire settings 260062
Accessories for GAP see page 42
• Plasma welding• Micro plasma welding• Touch screen setting technology• Monitoring of external cooling units• Works with WF cold wire feeder• Hand held torch or machine torches available• TIG welding & cold wire TIG welding• Plasma powder welding
EuTronic GAP 3001 DC
Technical dataVoltage supply 3x400 + N ± 10%
Power supply 5X16A CEE plug
Supply frequency 50/60 Hz
Welding current (50%ED) 350A
Welding current (100%ED) 250A
Adjustment range 6 - 350A
Max power consumption 20 KVA
Open circuit V main inverter 80 V
Open circuit V pilot inverter 110 V
Pilot current(100%ED) 30A
Adjustment range pilot current 3 - 60A
Protection index IP 23
Dimensions L x W x H (mm) 815x445x635
Weight 77 Kg
EuTronic GAP 3001 DC 260065
Accessories for GAP see page 42
• For full automation or manual operations• Plasma welding• Powerful PLC 72 pin harting plug automated interfaces (on request)• 100 memory cells for parameter storage• Powder coating using powder feeder EP2
• Optional GAP control software package for enhanced control and display of parameters• Works with cold wire feeder WF• Hand held and machine torches for both welding and powder coatings
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42
Plasma Transferred Arc & Powder Coating
EuTronic GAP 3002 AC/DC
Technical dataVoltage supply 3x400 + N ± 10%
Power supply 5X32A CEE plug 6mm2
Supply frequency 50/60 Hz
Welding current(60%ED) 380A
Welding current(100%ED) 280A
Adjustment range 6 - 380A
Max power consumption 20 KVA
Open circuit V main inverter 80 V DC
Open circuit V pilot inverter 110 V DC
Pilot current(100%ED) 30A
Adjustment range pilot current 3 - 60A
Protection index IP 23
Dimensions L x W x H (mm) 750X430X630
Weight 85 Kg
EuTronic GAP 3002 AC/DC 300995
• AC/DC plasma welding facilities• AC ARC for aluminium plasma welding• For full automation or manual operations• Powerful PLC 72 pin harting plug automation interface (available on request)• 100 memory cells for parameter storage• Optional GAP control software package for enhanced control and display of parameters• Works with cold wire feeder WF• Powder coating using Powder Feeder EP2• Hand held and machine torches for both welding and powder coating
EuTronic GAP Automated UnitTechnical dataGas supply Ar + AR/H2, @ 30 psi
Water supply 5 l/min
Supply voltage 460V 3 phases 60 Hz
Max. power consumption 20 kva
Welding current (100% duty cycle) 220 amps
Welding current adjustment range 6-280 amps
Open circuit voltage 80 volts
Pilot current at 100% duty 30 amps
Pilot current adjustment range 3-60 amps
Dimensions (LxWxH) 1795x750x2500mm
Weight 350kg
• Provides repeatable precision for plasma joining, coating and brazing • Turn-key robotic cell to increase productivity • AC/DC version available for welding of Al, Mg and their alloys • Completely modular for immediate, tailor made configuration
and cost effective fitting of applications • Wide range of options, accessories and welding consumables • Alloy fexibility
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Plasma Transferred Arc & Powder Coating
The new EuTronic GAP range of power sources, due to their modular design, can be adapted to any application just by choosing the appropriate accessories.
Accessories for GAP
Powder Feeder EP2
Technical dataSuitable for GAP 2000/3000 MPM
Carrier gas Ar, Ar-H2
Carrier gas flow rate 0 - 4 l/min
Powder reservoir 2 l capacity
Degree of protection IP 23
Weight (without powder) 7.5 kg
Dimensions L x W x H (mm) 200 x 170 x 470 mm
Powder Feeder EP2 260229
• Stepless feeding rate control via feeding wheel speed directly from inverter PLC. • Powder feed rate 3-120 g/min, depending on feeding wheel configuration, torch, anode and powder density.• Two EP2 units can be driven in parallel (only by power sources with the optional second motor control card) for applications that require feeding of different powders into the weld pool: i.e. matrix and carbides.
Cold Wire Feeder For GAP 2001 series / 3001 and 3002Degree of protection IP23
Weight 25 Kg
Dimensions L x W x H (mm) 725 x 230 x 450
Cold Wire Feeder 260395
• Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder for 16 Kg wire coils. • Special designed pressure arms care for a smooth and reproducible pressure of the wire onto the feeder rolls within the drive.
Cold Wire Feeder ElectronicFor MPM / TIG seriesPower supply 230VAC
Max. power consumption 370VA
Max.wire speed 10m/min
Suitable wire diameters 0.8 – 3.2 mm
Weight 30 Kg
Cold Wire Feeder Electronic 260425
• Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder for 16 Kg wire coils. • Special designed pressure arms care for a smooth and reproducible pressure of the wire onto the feeder rolls within the drive.• Electonically motor controller for the four roll wire feeder. Functions: forward/backward movement, wire inching, wire feedback, pulse functions, control signals for fault indication. • Buttons for: wire inching, forward/backward movement, speed and pulse adjustment.
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Plasma Transferred Arc & Powder Coating
RC-H manual
RC-H auto
Remote control units RC-H manual remote control 260231
including 8 metres connecting cable
RC-F foot operated remote control (pedal) 260232
including 8 metres connecting cable
RC-H auto remote control 260231
including 8 metres connecting cable
Cooling GAP *Technical dataWeight 40 kg
Dimensions L x W x H (mm)) 900 x 445 x 360mm
Cooling GAP (*) 260058
Technical dataWeight 45 kg
Dimensions L x W x H (mm) 900 x 445 x 360mm
Cooling GAP Twin 260059
(*) Use only Castolin Eutectic dedicated cooling liquid
• Single or twin circuit heat exchangers additional water-water heat exchanger available.
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Plasma Transferred Arc & Powder Coating
TrolleyTechnical dataWeight 45 kg
Dimensions L x W x H (mm) 1.190 x 740 x 1.415 mm
Trolley 260056
• Holds gas cylinders, powder feeder, power source and cooler.• Wide range of additional trays and accessories for better configuration and ease of use of the trolley.
Oscillating Unit Electronic OU 260314
Oscillation width 60 mm max
Oscillation speed 0,1 - 60 mm/s
Dwell time 0 - unlimited
Max load 5 Kg
Electronic AVC 260315
Max transverse path 100 mm
Oscillation speed 0,1 - 20 mm/s
Max load 10 Kg
Electronic OU with AVC 260316
The system allows oscillation while keeping the distance
from the workpiece constant.
The max load 5kg
Control Box 260519
Supply voltage 230V AC 50/60Hz
Degree of protection IP 23
Weight 20 kg
Dimensions L x W x H (mm) 564 x 264 x 440mm
The oscillator units are available in 3 different versions: basic OU, Oscillator Unit, an Arc Voltage Control option, AVC, that keeps the distance between torch and workpiece constant and a OU with AVC option (2 axis oscillator).
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Plasma Transferred Arc & Powder Coating
GAP E15 Construction horizontal
Max current at 100% 150A
Powder flow rate N.A
Weight with hose pack ca. 2.5 kg (4m)
GAP E15 260581 (4 m) 260622 (8 m)
• liquid cooled manual torch, available also with 70° and 180° neck• Hose pack: 4-6-8 metres; longer hose packs on request• Cold wire holder available
GAP E150Construction horizontal
Max current at 100% 150A
Powder flow rate ** 5-20 g/min
Weight with hose pack 2.0 kg (3m)
GAP E150 260434 (3 m) 260435 (4 m)
• 3m hose pack• Liquid cooled• Powder manual torch
GAP E54 S-M-D-DLConstruction horizontal
Max current at 100% 200A
Powder flow rate ** 10 - 40 g/min
GAP E54 (length: 330 mm) 400861 (4 m) 400715 (10 m)GAP E54 (length: 550 mm) 402272 (4 m) 402260 (10 m)
• Powder machine torch for inner coatings of parts with diameter > 80mm• Available in four different lengths (models): 330(S), 550(M), 920(D) and 1770(DL)mm. • With various hose pack lengths• Built on request, please ask for delivery time
GAP E52Construction vertical
Max current at 100% 200A
Powder flow rate ** 3 - 80 g/min
Weight with hose pack 4.8 kg (4m)
GAP E52 400204 (4 m) 400878 (6 m) 260230 (8 m)
• Liquid cooled powder machine torch for general applications• Cold wire holder available• Hose pack: 4-6-8 metres; longer hose packs on request• Wide range of anodes and powder nozzles
GAP E42Construction vertical
Max current at 100% 200A
Powder flow rate ** 3 - 140 g/min
Weight with hose pack 3.7 kg (4m)
GAP E42 400238 (4 m) 400240 (10 m)
• liquid cooled powder machine torch for high duty applications• Cold wire holder available
GAP torches
GAP E12N Construction horizontal
Max current at 100% 100A
Powder flow rate N.A
Weight with hose pack 1.9 kg (4m)
GAP E12N 400900 (4 m) 402420 (6 m) 402501 (8 m)
• liquid cooled manual torch, available also with 70° and 180° neck• Hose pack: 4-6-8 metres; longer hose packs on request• Cold wire holder available
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TeroMatec Wire Feeder 400
Technical dataVoltage supply 28 VDC max
Power 98 W
Welding Current 100-400 A
Corrente nominal 400 A
Open circuit voltage 80 V max
Duty cycle 100%
Wire speed 12m/min
Wire diameter range 1.6/2.4/2.8
Dimensions L x W x H (mm) 560 x 255 x 835
Weight 24 Kg
GoodAire 1202Consider consulting Castolin Eutectic for fume extraction torches, work benches and arms for fixed installations.
Technical DataPower supply 230 V single-phase
Effective flow rate 1000 m3/h
Noise level 60 dB(A) per DIN 45635
Weight 69 Kg
GoodAire 1202 1202
IDweld 2501
IDweld 2501 is a unit for welding, circular exteriors and interiors intended mainly for coating of internal bores from Ø 30 mm.A modular mechanical unit rotates, and depending on the application also drives a MIG welding head. This head is fitted with a special compact torch, which produces very high quality circumferential weld deposits, even in very tight spaces.The main fields of application are weld coating of internal bores, interior and exterior circular butt weld joints, tube passage joint welds.A large range of accessories extends the potential field of applications.
Technical DataVertical displacement 170 mm
Rotational speed 0.3 to 12 RPM
Power supply 1 x 230 V
Weight 19 Kg
Torch 41800 B
IDweld 2501 305339
• Internal & external bore welding machine• Can be used with any conventional MIG/MAG machine• Easy to set up• For internal bores down to 30mm diameter• Separate control box• Self-indexing vertically• Variable speed• Water-cooled head available• Torch extension kit supplied
• Very high effective suction• Cleanable filter• Dust recovery
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Notes
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Notes
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For all other countries or other information needed, please visit our website www.castolin.com
PICTURES Régis Colombo, Tom Coakley, archives Castol in Eutec tic GRAPHICS Phi l Gschwend, Trafikdesign.Statement of L iabi l i ty: Due to variations inherent in specif ic applications, the technical information contained herein, including any information as to suggest produc t applications or results, is presented without representation or warranty, expressed or implied. Without l imitation, there are no warranties of merchantabi l ity or of f i tness for a par ticular purpose . Each process and application must be ful ly evaluated by the user in al l respec ts, including suitabi l ity, compliance with applicable law and non-infringement of the r ights of others, and Messer Castol in Eutec tic and its aff i l iates shal l have no l iabi l i ty in respec t there of.
© Castolin Eutec tic - 2008
ADDRESSES OF CASTOLIN EUTECTIC COMPANIES IN EUROPEAustria, Hungary, South East EuropeCastolin GmbHBrunner Strasse 691235 Wien+43-(0)1-869 45 41-0
Belgium Messer Eutectic Castolin Benelux222-228, Blvd de l’Humanité1190 Bruxelles+32 (0)2-370-1302
Czech RepublicMesser Eutectic Castolin spol. s r.o.Trojska 80/122182 00 Praha 8+42 (0)2-83-09-00-77
FranceMESSER Eutectic Castolin Sàrl22, Av. du Québec BP 325Z.A. Courtaboeuf 1- Villebon91958 Courtaboeuf Cedex+33-(0)1-69 82 69 82
GermanyCastolin GmbHGutenbergstrasse 1065830 Kriftel+49-(0)6192-403-0
PortugalCastolin PortugalRua Maestro Ferrer Trindade, 4B2770-201 Paco de Arcos+351 707 200 855
NetherlandsCastolin Benelux N.V.Rotterdamseweg 4062629 HH Delft+31-(0)15-256 9203
NorwayCastolin Scandinavia Teknologiparken, Akersvn. 24 C 0177 Oslo +47-22-11 18 70
PolandMESSER Eutectic Castolin Sp.z.o.o.P.O. Box 502, ul. Robotnicza 244-100 Gliwice+48-(0)32-230 6736
SpainCastolin Iberica S.A.P. I. de Alcobendasc/ San Rafael, 628108 Alcobendas (Madrid)+34-914 900 300
Sweden, Denmark, FinlandCastolin Scandinavia ABTransportgatan 3742204 Hisings-Backa+46-(0)31-570 470
LithuaniaMesser Eutectic Castolin Sp.z.o.o.filialasV. Nageviciaus 3-6408237 Vilnius+370 5 278 8448
Switzerland MESSER Eutectic Castolin Switzerland SASwiss Market CentreCh. de la Venoge 71025 St. Sulpice+41-(0)21 694 1111
RussiaMesser Cutting & Welding OOOUl. Bolschaja Tulskajya 10/9Office 9506115191 Moscow
TurkeyCastolin Kaynak Ltd.Yukari Dudullu MahallesiBostanci Yolu Sehit Sokak 5334775 Istanbul
United Kingdom & IrelandEutectic Company Ltd.Merse RoadNorth Moons MoatRedditchWorcestershire B98 9NZUK+44-(0)1527 58 2200
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