Welding Equipment Catalogue 2008-English 13.08

Castolin Eutectic Welding Equipment
Joining Solutions
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Castolin Eutectic
Welcome contents
CASTOLIN Eutectic
History of Castolin Eutectic R&D / Technical Support Welding Consumables Production Training Local Support Professional Installation Products 4 5 6 7 8-9 10
MIG/MAG Welding Process

Metal Inert Gas/Metal Active Gas Welding XuperMIG 2500 Accessories XuperMIG 2500 CastoMIG 160C Accessories for CastoMIG 160C and 250C CastoMIG 250 C and 350 C / 350DS CastoMIG 400C / 400DS and 500C / 500DS 2 rolls system 11 4 rolls system / 2 rolls system Accessories for CastoMIG 350C and DS Accessories for CastoMIG 400/500 C and DS 13 14 14 15 16 16 17 17 Total Arc 3000 (compact) (liftarc)
2 2 2
27 28 28 29 29 29 31 32 32 33 33 34 35 36 36 37 37
Technical Data
Welding Processes Selection
MMA Welding Process

Manual Metal Arc Welding UltraMax inverter (liftarc)
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Total Arc 4000 (separate wire feeder)(liftarc) Total Arc 5000 (separate wire feeder)(liftarc) Accessories for Total Arc 3000 / 4000 and 5000
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PowerMax inverter (liftarc) XuperMax inverter (liftarc)

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CastoMatec 305 (liftarc) CastoMatec Xuper 455 CastoMatec Xuper 655 Accessories CastoMatec
Torches for MIG/MAG welding MIG/MAG torches selection
PTA Process
Plasma Transferred Arc Process 39 40 40 41 41 42 42 43-44 45 Multi Plasma Module
TIG Welding Process

Tungsten Inert Gas Welding CastoTIG 1501 DC CastoTIG 1701 DC CastoTIG 2201 DC and CastoTIG 3011/12 AC/DC CastoTIG 1702 AC/DC and 2202 AC/DC Electronic Wire Feeder Accessories for CastoTIG 1701/2 2201/2 TIG torches selection 19 20 20 21 22 22 23 23 - 24
EuTronic GAP 2001 DC basic EuTronic GAP 2001 DC touch screen EuTronic GAP 3001 DC EuTronic GAP 3002 AC/DC EuTronic GAP Automated Unit Accessories for GAP GAP torches
Special Products Plasma Cutting Process

Plasma Arc Cutting AirJet 65 AirJet 105 25 26 26 Addresses of Castolin Eutectic Companies in Europe 50 IDweld 2501 GoodAire 1202 TeroMatec Wire Feeder 400 46 46 46
symbols used
EutecTrode
CastoTig
EnDOtec
CastoMag
Three phase
Single phase
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-> www.castolin.com -> www.eutectic.com
Castolin Eutectic history of castolin eutectic

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 Corporation in New York . 1952 Foundation of Castolin France. 1959 Foundation of Eutectic Japan Ltd. 1962 Foundation of Eutectic India Ltd. 1960s International consolidation under Castolin Eutectic. 1970s Creation of training centers for Maintenance & Repair technologies. 1978 Establishment of World Head Quarters in StSulpice, 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.
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Castolin Eutectic r&d / technical support

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 MicroHardness 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 TV approval for several electrodes and flux cored wires.
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Castolin Eutectic welding 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 Eutectic training

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 local support
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.
TeroLink
Castolin 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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Castolininstallation products Eutectic professional

Castolin Eutectic takes great care in complying with following standards and recommendations for key organisations like TV, 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 Data welding processes selection

CastoTig Current (A) Alumi ni um Tec hnology E utec Trode Voltage (V ) Cas toM ag Stai nles s s teel E nDOtec Steel
Produc ts
U ltra Ma x 2 Pow erMa x Xup erMa x
2
Process
M MA M MA M MA M MA M MA M MA TI G TI G TI G TI G TI G P las ma Cut t i ng P las ma Cut t i ng M IG M IG M IG M IG M IG M IG M IG p uls e M IG p uls e M IG p uls e
230 230 380 380 380 380 230 230 230 230 230 380 380 380 400 230 380 380 380 380 380 380 380
140 150 250 300 450 650 150 170 170 220 220 300 65 105 150 160 240 300 370 500 270 400 500
I nve r te r I nve r te r I nve r te r T hy ris to r T hy ris to r T hy ris to r I nve r te r I nve r te r D ig ital inve r t e r D ig ital inve r t e r D ig ital inve r t e r I nve r te r I nve r t e r I nve r te r S te p s w it c h S t e p s w it c h S te p s w it c h S t e p s w it c h S te p s w it c h S t e p s w it c h I nve r te r I nve r te r I nve r t e r
CastoMa te c 305 CastoMa te c Xup er 455 CastoMa te c Xup er 655 CastoTIG 1501 DC CastoTIG 1701 DC CastoTIG 1702 AC/ D C CastoTIG 2201 DC CastoTIG 2202 AC/ D C Ai rJet 65 Ai rJet 105 Xup erMIG 2500 CastoMIG 160C CastoMIG 250 C CastoMIG 350 C, D S CastoMIG 400 C, D S CastoMIG 500 C, D S TotalArc 2 3000 Tot alArc 2 4000 TotalArc 2 5000
CastoTIG 3011/12 AC/ D C TI G
Recommended va ri ant
Po s s ib l e va ria nt
n o t re co m m e n de d va ria nt
Base Metal
Carbon / alloy steels S tainless ste els Alum inium / alloy s Ti t a nium / alloys Cast irons Cop p er / alloys Ma g nesium / alloy s
EutecTrode
CastoMag
EnDOtec
CastoTig
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MMA metal arc weldingProcess Welding manual

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.
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
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MMA Weld i ng
UltraMax2 inverter (liftarc)
Technical data
Welding amperage range 35% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 5 A - 140 A 140 A 100 A (at 40 C) 54 V 230 V 50/60 Hz 4.6 kVA 16 A IP 23 310 x 120 x 215 4.3 Kg 305650 305730 301054 304335 300826 301669
UltraMax2
Earth cable, 3m, 16mm2 Welding cable, 4m, 16mm2
Options
Welding cable XuperFlex with ergonomic electrode holder Conversion cable for TIG-Torch Gas regulator
TIG torches and wear parts see page 24 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 Light, compact and robust Voltage compensator Spike protector Fully portable
PowerMax inverter (liftarc)

Technical data
Welding amperage range 35% Duty cycle amperage 100%Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 10 A - 150 A 140 A 80 A (at 40 C) 92 V 230 V 50/60 Hz 3.6 kVA 16 A IP 23 315 x 110 x 200 4.7 Kg 304300 300789 301094
PowerMax
Includes Earth cable, 3m, 16mm2 Welding cable, 4m, 16mm2
Options
Welding cable XuperFlex with ergonomic electrode holder Conversion Cable for TIG-Torch Gas regulator 304335 300826 301669
TIG torches and wear parts see page 24 Advanced inverter technology Possiblity to weld cellulosic electrodes Power generator compatible TIG DC welding with 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
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MMA Weld i ng
XuperMax2 inverter (liftarc)
Technical data
Welding amperage range 40% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 10 A - 250 A 250 A 160 A (at 40C) 76 V 3 x 400 V 50/60 Hz 12.1 kVA 20 A IP 23 460 x 230 x 325 16 Kg 305900 303180 303181 300843 302240 302241 302242 302243 301669 303197 303119 303184 303192
XuperMax2
Includes Earth cable with plug and workpiece clamp (4m, 35mm2) Welding cable wih plug and electrode holder (4m, 35mm2)
Accessories
Remote control RCT DC Remote control cable (0.75m) Remote control cable (5m) Remote control cable (10m) Remote control cable (15m) Argon gas regulator
Options
Earth cable with plug and workpiece clamp (6m, 50mm2) Welding cable wih plug and electrode holder (6m, 50mm2) XuperFlex welding cable (yellow, 4m, 35mm2) with plug and ECO electrode holder XuperFlex welding cable (red, 6m, 50mm2) with plug and ECO electrode holder
TIG torches and wear parts see page 24 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 Weld i ng
CastoMatec 305 (liftarc)
Technical data
Welding amperage range 35% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Voltage at striking Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 5 A - 300 A 300 A 230 A 180 A 75 V 55 V 3 x 230V /400V 50/60 Hz 8.9 kVA 35A/230V - 20A/400V IP 23 675 x 500 x 450 95 Kg 303115
CastoMatec 305
With 3m main cable and CEE 32A plug
Accessories
Gasregulator 301633 303076 303080
Options
Digital ammeter Single lug lifting bar
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
CastoMatec Xuper 455

Technical data
Welding amperage range 35% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 5 A - 450 A 450 A 340 A 260A 75 V 3 x 230V / 400V / 500 V / 50/60 Hz 18.5 kVA 80A/230V -50A/400V IP 23 950 x 740 x 670 240 Kg 302790

Options
Digital ammeter Accessories for air-carbon arc gouging 302792 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
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MMA Weld i ng
Technical data
Welding amperage range 35% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 5 A - 650 A 650 A 490 A 380 A 75 V 3 x 230V /400V / 500 V / 50/60 Hz 26 kVA 100A/230V -63A/400V IP 23 950 x 740 x 670 284 Kg 303170

Options
Digital ammeter Accessories for air-carbon arc gouging 302792 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
Options
Welding cable XuperFlex with with plug and Eco electrode holder (red, 4 m, 50 mm2) Welding cable, 6 m, 50 mm2, with plug and electrode holder 400 A Earth cable, 6 m, 50 mm2, with plug and 400 A electrode holder Earth cable, 6 m, 50 mm2, with plug 400 A workpiece clamp Remote control unit FR 3-1 for current setting Remote control cable for Remote control unit FR 3-1 (10 m) Remote control cable for Remote control unit FR 3-1 (20m) Remote control cable for Remote control unit FR 3-1 (30m) 303192 303119 303197 303118 303075 303077 303078 303079
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TIG Welding Process tungsten 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.
1) Gas nozzle - 2) Gas shielding - 3) Filler rod - 4) Weld pool 5) Weld bead - 6) Parent metal
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TI G Weldi n g DC
CastoTIG 1501 DC
Technical data
Welding amperage range 35% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 5 A - 150 A (TIG) 140 A (MMA) 150 A 100 A 54 V 230 V single-phase 50/60 Hz 5.9 kVA 16 A IP 23 360 x 120 x 215 5.7 Kg 305300 301094 300789 301669
CastoTIG 1501 DC Options

Welding cable, 4m Earth Cable, 3m Gas regulator
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 data
Welding amperage range 35% Duty cycle amperage 100% Duty cycle amperage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 3 - 170 A (TIG) - 140 A (MMA) 170 A 110 A 92 V 230 V single-phase 50/60Hz 3.3 kVA 16 A IP 23 485 x 175 x 345 10 Kg 304400 303181 303180 301669

Welding cable, 4m Earth cable, 3m, 35mm2 Gas regulator
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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TI G Weldi n g DC
CastoTIG 2201 DC
Technical data
Welding amperage range (TIG) Electrode Welding amperage 35% Duty cycle 60% Duty cycle 100% Duty cycle Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 3 A-220 A 10 A-180 A 220 A 170 A 140 A 84 V 1 x 230 V / 50/60 Hz 2.7 kVA 16 A IP 23 500 x 175 x 410 16.8 kg 304901 304960

Watercooling 2200
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/DC

Technical data
Welding amperage range Duty cycle 45% Duty cycle 100% Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x l x H (mm) Weight CastoTIG 3011 DC Weight CastoTIG 3012 AC/DC 3 - 300 A (TIG) 10 - 300 A (MMA) 300 A 230 A 85 V 3 X 400 V +/- 15% 6.1 kVA 16 A IP 23 590 x 245 x 450 23 kg 27 kg 307500 307600 300255 307615 307580
CastoTIG 3011 DC CastoTIG 3012 AC/DC Options

Remote control RC2 Trolley cooling 3011/3012
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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TI G Weldi n g AC /DC
CastoTIG 1702 AC/DC and 2202 AC/DC
Technical data
Welding amperage range (TIG) Electrode Welding amperage 30% Duty cycle 60% Duty cycle 100% Duty cycle Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight
1702 AC/DC
3 A - 170 A 10 A-140 A 170 A 120 A 90 A 90 V 1 x 230 V / 50/60 Hz 3.0 kVA 16 A IP 23 500 x 175 x 410 15 kg 304900
2202 AC/DC
3 A-220A 10 A-180 220 A 160 A 130 A 93 V 1 x 230 V / 50/60 Hz 3.0 kVA 16 A IP 23 500 x 175 x 410 17.3 kg 304902
CastoTIG 1702 AC/DC and 2202 AC/DC Options

Watercooling 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
Electronic Wire Feeder

Power supply Max. power consumption Max.wire speed Suitable wire diameters Weight 230VAC 370VA 10m/min 0.8 3.2 mm 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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TI G Weldi n g A ccessor ie s a n d To rc h e s
Accessories for CastoTIG 1701/2 2201/2
Options
Earth cable (4m, 35mm2) Remote control RCT DC Remote control RCT AC Remote control RCT P Remote control unit RCT F Cooling Trolley with gas cylinder
1701DC
303180 300843 300845 300846 304440
1702AC/DC
303180 300255 300256 304973 304440
2201DC
303180 300255 304973 304960 304440
2202AC/DC
303180 300255 300256 304973 304960 304440
TIG torches selection

Gas cooled Torches with manuel gas valve
G 140 RA G 220 RA 110 A = / 95 A ~ at 60% Duty cycle 220 A = / 200 A ~ at 40% Duty cycle 90 A = / 50 A ~ at 35% Duty cycle 160 A = / 140 A ~ at 40% Duty cycle 220 A = / 200 A ~ at 40% Duty cycle 200 A = / 180 A ~ at 35% Duty cycle 220 A = / 200 A ~ at 100% Duty cycle 400 A = / 360 A ~ at 60% Duty cycle
4 m Article
301715 301238 301279 304120 301153 305000 304986 500264
8 m Article
301719 301241 301282 304121 301156 305001 304990 500265
Gas cooled Torches

G 90 UD/D G 160 G 220 UD/D G221 U/ D
Water cooled Torches

W 201 UD/D W 400 B1/UD
G 140 RA
G 220 UD/D
G 221 UD/D
W 400 B1/UD
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TI G Weldi n g t orch es
TIG torches selection
ESC Cas toM atec 305 XuperM ax 2 Equipment Cas toTIG 1701 DC 1702 AC/DC Cas toTIG 2201 DC 2202 AC/DC
PowerM ax
UltraM ax 2
TotalArc 2
TIG welding torches

G9 0 U D/D G1 40 RA G1 60 G2 20 RA G2 20 U D/D G2 21 U D/D W201 U D/D W400 B1/U D
4m
301279 301715 304120 301238 301238 305000 305000 500264
8m
301282 301719 304121 301241 301156 305001 304990 500265
Cas toTIG 1501 DC
Co o l in g 2 2 0 0 Co o l ing 2 2 0 0 Co o l in g 2 2 0 0 Co o l in g 2 2 0 0
Recommended va ri ant
N o t re co m m e n de d va ria nt
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Plasma cutting Cutting Process plasma arc

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.
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Plasma C u t t i ng
AirJet 65
Technical Data
Cutting thickness (mild steel) capacity Repair Severing Amperage range Open circuit voltage Power supply Max. input power Protection index Compressed Air required Max. air consumption Weight Dimensions L x W x H (mm) about 10 mm 15 mm 20 mm 20 - 65 A 540 V 3 x 400 V 9 kVA IP 23 5 bar 130 l/min 18 Kg 586 x 215 x 385 306600
AirJet 65
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 Data
Cutting thickness (mild steel) capacity Repair Severing Amperage range Open circuit voltage Power supply Max. input power Protection index Compressed Air required Max. air consumption Weight Dimensions L x W x H (mm) about 20 mm 30 mm 40 mm 20 - 105 A 540 V 3 x 400 V 15 kVA IP 23 5 bar 180 l/min 28 Kg 711 x 275 x 500 306500
AirJet 105
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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MIG/MAG Weldingwelding Process metal inert gas/metal active gas

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.
1) Gas nozzle - 2) Contact tube - 3) solid/cored wire 4) Gas shield - 5) Arc - 6) Weld pool - 7) Weld metal 8) Parent metal
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MI G /MAG Weld i ng
XuperMIG 2500
Technical Data
Welding amperage range MIG/MAG duty cycle MMA duty cycle TIG duty cycle Fuse rating Power supply Open circuit voltage (MIG/MAG, MMA, TIG) Protection Index Insulation class Cooling Weight Dimensions L x W x H (mm) 5 250 A 30%: 250 A / 26.5 V 100%: 140 A / 21 V 40%: 200 A / 28 V 100%: 130 A / 25.2 V 40%: 200 A / 18 V 100%: 130 A / 12.2 V 16 A 3 X 400 V + 15% 50-60 Hz 9 V / 76 V / 9 V IP 23 H AF 22 Kg 670 x 310 x 490 mm
MIG/MAG torches and wear parts see page 37 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
Accessories for XuperMIG 2500

XuperMIG 25oo CastoPlus Torch 250G/3m CastoPlus Torch 250G/4m Torch TIG WT26 4m XuperMIG Torch TIG WT26 8m XuperMIG Earth cable 3,5m 35mm2 307200 303802 303803 307151 307152 301061
TIG torches will be changed due to the plug
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MI G /MAG Weld i ng
CastoMIG 160C
Technical data
Welding amperage range 30% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Number of arc voltage positions Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 30 - 160 A 100 A 60 A 15.5 21.5 V 37 V 6 1 x 230 V 10% 50/60 H 2.7 kVA /100 % 16 A IP 21 785 x 490 x 710 61 Kg 304033
CastoMIG 160C
Includes Earth cable, 3m, 35mm2 with plug and workpiece clamp Shielding gas hose, 1.5m
301061 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 Argon/CO2 gas regulator Adaptor diam.185mm Earth cable, 3m, 35mm2 with plug and workpiece clamp 303426 301669 300005 301061
Wire feeding rolls

Drive roll with trapezoidal groove for solid wires diam.0.8mm Drive roll with trapezoidal groove for solid wires diam.1mm 303433 303434
Pressure rolls
Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm 303467 302762 303468 303763 303469 303755
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MI G /MAG Weld i ng
CastoMIG 250C and 350C / 350DS
CastoMIG 250C
Technical data
Welding amperage range 30% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Number of arc voltage positions Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight
CastoMIG 350C
250C
25 - 240 A 240 A 130 A a15.8 - 26 V 37 V 10 3 x 400/3 x 230 V 15% 50/60 Hz 3.7 kVA /100 % 10 AT/400 V / 20 AT/230 V IP 21 785 x 490 x 710 74 Kg
CastoMIG 350DS
separate Wire Feeder
350C / 350DS
20 -340 A (350C) / 20 -300 A (350DS) 300A 210 A (240 A at 25 C) 140 A 15 - 31 V 43 V 15 3 x 400/3 x 230 V 15% 50/60 Hz 4.1 kVA /100 % Duty cycle 20 AT/400 V / 25 AT /230 V IP 21 785 x 490 x 810 101 Kg (350C) / 97 KG (350DS)
CastoMIG
CastoMIG 250C with four roll drive, earth cable and gas hose CastoMIG 350C with two roll drive, earth cable and gas hose: CastoMIG 350C with four roll drive, earth cable and gas hose CastoMIG 350 DS with earth cable and gas hose: 303400 303400 (350C) / 303404 (350DS) 303402 (350C) / 303405 (350DS) 303403 (350DS)
Includes
Earth cable, 3m, 35mm2 with plug and workpiece clamp Earth cable, 4m, 50mm2 with plug and workpiece clamp Shielding gas hose, 1.5m Holder for DS I Wirefeeder CastoMIG DS I 2-Roll 301061 300693 303483 300693 (350C) 303436 (350DS) 303404 (350DS)
Options/Accessories for CastoMIG 350C/DS
MIG/MAG torches and wear parts see page 37 Conversion kit 4 rolls feeder for CastoMIG 350 C/DS more see page 32 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
30
MI G/MAG Weld i n g
CastoMIG 400C / 400DS and 500C / 500DS
CastoMIG 400C
Compact
CastoMIG 400DS
CastoMIG 500C
Compact
CastoMIG 500DS
Technical data
Welding amperage range 30% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Number of arc voltage positions Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight
400C / 400DS
30 - 370 A 370 A 280 A (300 A at 25C) 220 A (235 A at 25C) 15.5 - 32.5 V 43 V 21 3 x 400/ 3 x 230 V 15% 50/60 Hz 7.6 kVA / 100% 25 AT/ 400 V / 35 AT / 230 V IP 23 950 x 465 x 895 (C) / 950 x 465 x 785 (DS) 137 Kg (400C) / 129 Kg (400DS) 303406 (400C) / 303408 (400DS) 303407 (400C) / 303409 (400DS)
500C / 500DS
35 - 500 A 500 A 360 A (410 A at 25C) 280 A (315 A at 25C) 15.8 - 39 V 54 V 28 3 x 400/ 3 x 230 V 15% 50/60 Hz 10.2 kVA / 100% 35 AT/ 400 V / 63 AT / 230 V IP 23 950 x 465 x 895 (C) / 950 x 465 x 785 (DS) 156 Kg (500C) / 148 Kg (500DS) 303410 (500C) / 303412 (500DS) 303411 (500C) / 303413 (500DS)
CastoMig
With switch synergic program CMP 45
Includes
Earth cable, 4m, 50mm2 with plug and workpiece clamp Earth cable, 4m, 70mm2 with plug and workpiece clamp Shielding gas hose, 1.5m 303483 300693 (400C) 303415 303484 300693 (500C)
Options / Accessories
Cooling CMC 47, 230V / 50Hz
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
31
MI G /MAG Weld i ng
2 Rolls system
1) Drive roll with groove 2) Feedroll with groove 3) Pressure roll smooth
Wire Diameter PCS

0.8 1.0 1.2 1.6 1 1 1 1
Drive roll with groove Article

303467 303468 303469 303470
PCS
1 1 1 1
Feedroll with groove Article

302762 302763 302755 302764
PCS
-
Pressure roll smooth Article

-
Semi circular groove smooth steel teeth Aluminium + cored wire
Trapezoidal groove steel teeth Fe + CrNi
0.8 1.0 1.2 1.6
1 1 1 1
303433 * 303434 * 302695 303435
1 1 1 1
302852 * 302852 * 302852 * 302852 *
* Rolls without teeth
4 Rolls system / 2 Rolls system
2) Feedroll with groove 3) Pressure roll smooth 4) Drive gear
Wire Diameter PCS

Semi circular groove smooth steel teeth Aluminium + cored wire
0.8 1.0 1.2 1.6 42 42 42 42
Feedroll with groove Article

302762 302763 302755 302764
PCS
-
Pressure roll smooth Article

-
PCS
1 1 1 1
Drive gear Article

302756 302756 302756 302756
Trapezoidal groove steel teeth Fe + CrNi
0.8 1.0 1.2 1.6
21 21 21 21
302765 302766 302767 302768
21 21 21 21
302852 * 302852 * 302852 * 302852 *
1 302756 1 302756 1 302756 1 302756 * Rolls without teeth 1 1 1 1 1 302756 302756 302756 302756 302756
Semi circular groove knurled steel teeth Cored wire
1.2 1.6 2.0 2.4 2.8
42 42 42 42 42
302769 302770 302771 302772 302773
32
MI G /MAG Weld i ng
Accessories for CastoMIG 350C and DS
Conversion kit A/V - digital display Conversion kit socket for gas preheater, 230V / 2A Conversion kit soft start speed for 350C Conversion kit soft start speed for 350DS Trolley for DSI and DSII Holder for DSI Connexion cable assembly for DSI, 5m/10m Argon/CO2 pressure reducer Adaptor diam.185mm Earth cable, 4m, 50mm2 wih plug and workpiece clamp Drive roll with trapezoidal groove for solid wires diam.0.8mm Drive roll with trapezoidal groove for solid wires diam.1mm Drive roll with trapezoidal groove for solid wires diam.1.2mm Press roll Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.0.8mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.2mm Drive roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.6mm Feed roll with semi-circular groove for Al/Al-alloys and cored wires diam.1.6mm 303425 303426 303427 303428 303432 303436 30342(3/4) 301669 300005 301483 303433 303434 302695 302852 303467 302762 303468 303763 303469 303755 303470 303764
Accessories for CastoMIG 400/500 C and DS

Cooling CMC 47, 230V / 50Hz Conversion kit 4-roll feeder Feed roll, with trapezoidal groove for solid wire diam.1mm Feed roll, with trapezoidal groove for solid wire diam.1.2mm Pressure roll Connection cable assembly for DSII, gas cooled, 5m/10m Connection cable assembly for DSII, water cooled, 5m/10m Conversion kit push/pull for torch MSG816 Conversion kit socket for gas preheater, 230V / 2A Conversion kit Lifting eyes Conversion kit program unit CMP45 Conversion kit Control socket 9 poles Trolley for DSI and DSII Holder for DSII Cooling CMC 46, 230V, 50/60Hz, with rotating pump Argon/CO2 gas regulator Adaptor diam.185mm Earth cable, 4m, 50mm2 wih plug and workpiece clamp 303415 303421 302766 302767 302852 30341(7/8) 3034(19/20) 303429 303426 303431 303416 303549 303432 303422 303430 301669 300005 301483
33
MI G pu lse Weld i ng
Total Arc2 3000 (compact) (liftarc)
Technical data
Welding amperage range 40% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 3 - 270 A 270 A 210 A (270 A at 25C) 170 A (210 A at 25C) 14.2 - 27.5 V 50 V 3 x 400/ 50/60 Hz 4.5 kVA / 100% 16 AT/ 400 V IP 23 940 x 580 x 900 71 Kg 303650 303651 303713 300693
Total Arc2 3000

Digital Dual voltage
Includes
Programs display chart Shielding gas hose, 1.5m
Options
Earth cable, 3 m, 35 mm2 with plug and workpiece clamp Earth cable, 4 m, 70 mm2 with plug and workpiece clamp 301061 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
34
Total Arc2 4000 (separate wire feeder) (liftarc)
Technical data
Welding amperage range 40% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 3 - 400 A 400 A 365 A (400 A at 25C) 320 A (365 A at 25C) 14.2 - 34.0 V 70 V 3 x 400/ 50/60 Hz 12.7 kVA / 100% 35 AT/ 400 V IP 23 910 x 580 x 900 75 Kg 303740 303741
Total Arc2 4000

Includes
Operating manual&spare parts list Programs display chart Shielding gas hose, 1.5m 303741 303741 303741 303733 301061 303484
Wire feeder DS3 Earth cable, 3 m, 35 mm2 with plug and workpiece clamp Earth cable, 4 m, 70 mm2 with plug and workpiece clamp
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
35
Total Arc2 5000 (separate wire feeder) (liftarc)
Technical data
Welding amperage range 40% Duty cycle amperage 60% Duty cycle amperage 100% Duty cycle amperage Operating voltage Open circuit voltage Power supply Power at primary (100%) Fuse rating Protection index Dimensions L x W x H (mm) Weight 3 - 500 A 500 A 450 A (500 A at 25C) 360 A (450 A at 25C) 14.2 - 39.0 V 70 V 3 x 400/ 50/60 Hz 15.1 kVA / 100% 35 AT/ 400 V IP 23 910 x 580 x 900 75 Kg 303750 303751 303734 303733 303736 303484
Total Arc2 5000

Holder for DS III Wirefeeder CastoMIG DS III Connection cable assembly, 5 m Earthing cable, 6 m, 70 mm2
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 Remote control unit RC4 Remote control cable, 0.75m/5m/10m/15m/20m Argon/CO2 gas regulator Trolley for DSIII Holder for DSIII Interconnection cable assembly 1.5/5/10/15/20 Torch balancing boom XUPERlight Installation set for push/pull torch Interface AUT 2 for automatised applications External start button, with plug and 5m cable Interface for connecting TotalArc with a personal computer 300255 300256 30224(1/2/3/4) 301669 303432 303734 3037 (35/36/37/38/39) 303742 303718 303744 302652 303767
36
MI G pu lse Weld i n g
Torches for MIG/MAG welding
Gas cooled torches
CastoPlus 150 G CastoPlus 250 G CastoPlus 360 G 150 A = at 60 % Duty cycle 200 A = at 60 % Duty cycle 320 A = at 60 % Duty cycle 270 A = at 100 % Duty cycle 450 A = at 100 % Duty cycle 450 A = at 100 % Duty cycle 550 A = at 100 % Duty cycle
3m
30380 0 30380 2 30380 4 30380 7 30381 0 30381 3 30394 0
4m
30380 1 30380 3 30380 5 30380 8 30381 1 30381 4 30394 1
5m
30380 6 30380 9 30381 2 30381 5 30394 2
Water cooled torches

CastoPlus 300 W CastoPlus 500 W CastoPlus 500 W U/D CastoPlus 601 W
Water cooled torches for heavy duty EnDotec applications

MSG 400 FD 400 A = at 100 % Duty cycle
1.5 m
-
3m
302474
5m
-
Water cooled machine torches

MSG 350 MB MSG 500 MB 350 A = at 100 % Duty cycle 500 A = at 100 % Duty cycle 302254 302282 302288
Water Cooled push pull torches

MSG 816(A) 302439
302442
MIG/MAG Torches Selection

Equipment CastoMIG 400/500 C/DS/ W *** CastoMIG 350 C/ DS CastoMIG 160C TotalArc 2 3000/4000/5000
with push pu l l c a rd
CastoMIG 250C
MIG/MAG w elding torches

CastoPlus 150G CastoPlus 250G CastoPlus 360G CastoPlus 300W CastoPlus 500W CastoPlus 500W U/ D CastoPlus 601W MSG 400 F D MSG 350MB 1, 5m MSG 500MB MSG 816(A) 5m Id -Weld torch ga s co o led Id -Weld torch wa t er co o led
3m/4m/5m
303800/ 1 303802/ 3 303804/ 5/ 6 303807/ 8/ 9 303810/ 1/ 2 303813/ 4/ 5 303940/ 1/ 2 302474 302254 302282/ 302288 302439/ 302442 300587 300588
with push pull card
* * * w ith wa te rco o li n g
Recom mended va ri ant
n o t re co m m e n de d va ria nt
XuperMig 2500
CastoMIG 400/500 C/DS
37
38
PTA Process process plasma transferred arc

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.
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
39
Plasma Tra n sfer red A rc & Po wd e r Co a t in g Multi Plasma Module

Technical Data
Supply voltage Max power consumption Welding current TIG-inverter (60% ED) Welding current TIG-inverter (100% ED) Open-circuit voltage Adjustment range pilot current Protection type Dimensions L x W x H (mm) Weight 230V +N 50/60Hz 0.9kVA 270A 220A 110 V DC 5 - 20A IP 23 565 x 265 x 460 29 kg 1007495
Multi plasma module Options

Interconnecting cable PMB/Z-2m for CastoTig 1601DC / 1701DC / 1702AC/DC 2201 DC / 2202 AC/DC Interconnecting cable PMB/Z-2m for 3002AC/DC Al-Module for Multi Plasma Module WPL manual torch E12N, 4m Water-cooled, for plasma welding Liner unit for WFE, 3m
1002713 1002711 1004439 400900 260422
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
Expandable modular design An affordable start in plasma welding Separate power source required, see CastoTIG power source
EuTronic GAP 2001 DC basic

Technical data
Voltage supply Power supply Supply frequency Welding current(100%ED) Adjustment range Max power consumption Open circuit V main inverter Open circuit V pilot inverter Pilot current(100%ED) Adjustment range pilot current Protection index Dimensions L x W x H (mm) Weight 3x400 + N 10% 5X16A CEE plug 50/60 Hz 160A 1.0 - 160A 16 KVA 90 V 110 V 20A 5 - 20A IP 23 815x455x635 63 Kg 260234 260063
EuTronic GAP 2001 DC basic

with powder and Cold Wire settings
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
40
Plasma Tra n sfer red A rc & Po wd e r Co a t in g

EuTronic GAP 2001 DC touch screen
Technical data
Voltage supply Power supply Supply frequency Welding current(100%ED) Adjustment range Max power consumption Open circuit V main inverter Open circuit V pilot inverter Pilot current (100%ED) Adjustment range pilot current Protection index Dimensions L x W x H (mm) Weight 3x400 + N 10% 5X16A CEE plug 50/60 Hz 160A 1.0 - 160A 16 KVA 90 V 100 V 10A 0.5 - 10A IP 23 815x455x635 70 Kg 260233 260062
EuTronic GAP 2001 DC touch screen Option

Like basic with powder and Cold Wire settings
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 data
Voltage supply Power supply Supply frequency Welding current (50%ED) Welding current (100%ED) Adjustment range Max power consumption Open circuit V main inverter Open circuit V pilot inverter Pilot current(100%ED) Adjustment range pilot current Protection index Dimensions L x W x H (mm) Weight 3x400 + N 10% 5X16A CEE plug 50/60 Hz 350A 250A 6 - 350A 20 KVA 80 V 110 V 30A 3 - 60A IP 23 815x445x635 77 Kg 260065
EuTronic GAP 3001 DC

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
41

EuTronic GAP 3002 AC/DC
Technical data
Voltage supply Power supply Supply frequency Welding current(60%ED) Welding current(100%ED) Adjustment range Max power consumption Open circuit V main inverter Open circuit V pilot inverter Pilot current(100%ED) Adjustment range pilot current Protection index Dimensions L x W x H (mm) Weight 3x400 + N 10% 5X32A CEE plug 6mm2 50/60 Hz 380A 280A 6 - 380A 20 KVA 80 V DC 110 V DC 30A 3 - 60A IP 23 750X430X630 85 Kg 300995
EuTronic GAP 3002 AC/DC
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 Unit

Technical data
Gas supply Water supply Supply voltage Max. power consumption Welding current (100% duty cycle) Welding current adjustment range Open circuit voltage Pilot current at 100% duty Pilot current adjustment range Dimensions (LxWxH) Weight Ar + AR/H2, @ 30 psi 5 l/min 460V 3 phases 60 Hz 20 kva 220 amps 6-280 amps 80 volts 30 amps 3-60 amps 1795x750x2500mm 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
42

Accessories for GAP
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.
Powder Feeder EP2

Technical data
Suitable for GAP 2000/3000 MPM Carrier gas Carrier gas flow rate Powder reservoir Degree of protection Weight (without powder) Dimensions L x W x H (mm) Ar, Ar-H2 0 - 4 l/min 2 l capacity IP 23 7.5 kg 200 x 170 x 470 mm 260229
Powder Feeder EP2
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 3002
Degree of protection Weight Dimensions L x W x H (mm) IP23 25 Kg 725 x 230 x 450 260395
Cold Wire Feeder
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 Electronic

For MPM / TIG series
Power supply Max. power consumption Max.wire speed Suitable wire diameters Weight 230VAC 370VA 10m/min 0.8 3.2 mm 30 Kg 260425
Cold Wire Feeder Electronic
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.
43
Cooling GAP *
Technical data
Weight Dimensions L x W x H (mm)) 40 kg 900 x 445 x 360mm 260058
Cooling GAP (*) Technical data

Weight Dimensions L x W x H (mm)
45 kg 900 x 445 x 360mm 260059
Cooling GAP Twin
(*) Use only Castolin Eutectic dedicated cooling liquid Single or twin circuit heat exchangers additional water-water heat exchanger available.
Remote control units

RC-H manual remote control
including 8 metres connecting cable 260231
RC-F foot operated remote control (pedal) RC-H manual

including 8 metres connecting cable
260232
RC-H auto remote control

including 8 metres connecting cable
260231
RC-H auto
44
Trolley
Technical data
Weight Dimensions L x W x H (mm) 45 kg 1.190 x 740 x 1.415 mm 260056
Trolley
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
Oscillation width Oscillation speed Dwell time Max load 260314 60 mm max 0,1 - 60 mm/s 0 - unlimited 5 Kg 260315 100 mm 0,1 - 20 mm/s 10 Kg 260316
Electronic AVC
Max transverse path Oscillation speed Max load
Electronic OU with AVC

The system allows oscillation while keeping the distance from the workpiece constant. The max load
5kg 260519 230V AC 50/60Hz IP 23 20 kg 564 x 264 x 440mm
Control Box
Supply voltage Degree of protection Weight Dimensions L x W x H (mm)
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).
45
P lasma Tra nsfer red A rc & Po wd e r Co a t in g

GAP torches
GAP E12N
Construction horizontal Max current at 100% Powder flow rate Weight with hose pack 100A N.A 1.9 kg (4m) 402420 (6 m) 402501 (8 m)
GAP E15
Construction horizontal Max current at 100% Powder flow rate Weight with hose pack 150A N.A ca. 2.5 kg (4m) 260622 (8 m)
GAP E12N
400900 (4 m)
GAP E15
260581 (4 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
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 E150
Construction horizontal Max current at 100% Powder flow rate ** Weight with hose pack 150A 5-20 g/min 2.0 kg (3m) 260434 (3 m) 260435 (4 m)
GAP E54 S-M-D-DL

Construction horizontal Max current at 100% Powder flow rate ** 200A 10 - 40 g/min
GAP E150
3m hose pack Liquid cooled Powder manual torch
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 E52
Construction vertical Max current at 100% Powder flow rate ** Weight with hose pack 200A 3 - 80 g/min 4.8 kg (4m) 400878 (6 m) 260230 (8 m)
GAP E42
Construction vertical Max current at 100% Powder flow rate ** Weight with hose pack 200A 3 - 140 g/min 3.7 kg (4m) 400238 (4 m) 400240 (10 m)
GAP E52
400204 (4 m)
GAP E42
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
liquid cooled powder machine torch for high duty applications Cold wire holder available
46
IDweld 2501
IDweld 2501 is a unit for welding, circular exteriors and interiors intended mainly for coating of internal bores from 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 Data
Vertical displacement Rotational speed Power supply Weight Torch 170 mm 0.3 to 12 RPM 1 x 230 V 19 Kg 41800 B 305339
IDweld 2501
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
GoodAire 1202
Consider consulting Castolin Eutectic for fume extraction torches, work benches and arms for fixed installations.
Technical Data
Power supply Effective flow rate Noise level Weight 230 V single-phase 1000 m3/h 60 dB(A) per DIN 45635 69 Kg 1202
GoodAire 1202
Very high effective suction Cleanable filter Dust recovery
TeroMatec Wire Feeder 400

Technical data
Voltage supply Power Welding Current Corrente nominal Open circuit voltage Duty cycle Wire speed Wire diameter range Dimensions L x W x H (mm) Weight 28 VDC max 98 W 100-400 A 400 A 80 V max 100% 12m/min 1.6/2.4/2.8 560 x 255 x 835 24 Kg
47

Notes
48
Notes
49
ADDRESSES OF CASTOLIN EUTECTIC COMPANIES IN EUROPE

Austria, Hungary, South East Europe
Castolin GmbH Brunner Strasse 69 1235 Wien +43-(0)1-869 45 41-0
Netherlands
Castolin Benelux N.V. Rotterdamseweg 406 2629 HH Delft +31-(0)15-256 9203
Lithuania
Messer Eutectic Castolin Sp.z.o.o.filialas V. Nageviciaus 3-64 08237 Vilnius +370 5 278 8448
Norway
Castolin Scandinavia Teknologiparken, Akersvn. 24 C 0177 Oslo +47-22-11 18 70
Belgium
Messer Eutectic Castolin Benelux 222-228, Blvd de lHumanit 1190 Bruxelles +32 (0)2-370-1302
Switzerland
MESSER Eutectic Castolin Switzerland SA Swiss Market Centre Ch. de la Venoge 7 1025 St. Sulpice +41-(0)21 694 1111
Poland
MESSER Eutectic Castolin Sp.z.o.o. P.O. Box 502, ul. Robotnicza 2 44-100 Gliwice +48-(0)32-230 6736
Czech Republic
Messer Eutectic Castolin spol. s r.o. Trojska 80/122 182 00 Praha 8 +42 (0)2-83-09-00-77
Russia
Messer Cutting & Welding OOO Ul. Bolschaja Tulskajya 10/9 Office 9506 115191 Moscow
France
MESSER Eutectic Castolin Srl 22, Av. du Qubec BP 325 Z.A. Courtaboeuf 1- Villebon 91958 Courtaboeuf Cedex +33-(0)1-69 82 69 82
Spain
Castolin Iberica S.A. P. I. de Alcobendas c/ San Rafael, 6 28108 Alcobendas (Madrid) +34-914 900 300
Turkey
Castolin Kaynak Ltd. Yukari Dudullu Mahallesi Bostanci Yolu Sehit Sokak 53 34775 Istanbul
Germany
Castolin GmbH Gutenbergstrasse 10 65830 Kriftel +49-(0)6192-403-0
Sweden, Denmark, Finland

Castolin Scandinavia AB Transportgatan 37 42204 Hisings-Backa +46-(0)31-570 470
United Kingdom & Ireland

Eutectic Company Ltd. Merse Road North Moons Moat Redditch Worcestershire B98 9NZ UK +44-(0)1527 58 2200
Portugal
Castolin Portugal Rua Maestro Ferrer Trindade, 4B 2770-201 Paco de Arcos +351 707 200 855
For all other countries or other information needed, please visit our website www.castolin.com
PICTURES GRAPHICS
Rg i s Col om b o, To m Co ak ley, a rch ives Ca st o lin E utec tic P h i l G sc h w end , Tra f ikd esig n . S t a t em ent of L i ab i l i t y: Du e t o va r ia t io n s in h erent in specific applications, the technical information contained herein, includ i ng a ny i n for m a t i on a s t o su g g est p ro d u c t a p p lic a t io n s o r results, is presented w ithout representation or warranty, expressed or imp l i ed . Wi t h ou t l i m i t a t io n , t h ere a re n o wa r ra nt ies o f merchantability or of fitness for a par ticular purpose . Each process a nd a p p l i c at i on m ust b e fu lly evalu a t ed by t h e u ser in all respec ts, including suitability, compliance w ith applicable law and no nin f r i n g em ent of t h e rig ht s o f o t h er s, a n d M esser Ca st o lin Eutec tic and its affiliates shall have no liability in respec t there of. Ca s to li n E u t e c t i c - 2 0 0 8
50

Stronger, with... Castolin Eutectic

WEAR & FUSION TECHNOLOGY
Ask our Application Specialists for a demonstration

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Welding Equipment Catalogue 2008-English 13.08

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Welding Equipment Catalogue 2008-English 13.08

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Castolin Eutectic Welding Equipment

Stronger, with Catalogue

MIG/MAG Welding Process

MMA Welding Process

PowerMax inverter (liftarc) XuperMax inverter (liftarc)

Torches for MIG/MAG welding MIG/MAG torches selection

TIG Welding Process

Special Products Plasma Cutting Process

Castolin Eutectic history of castolin eutectic

Castolin Eutectic r&d / technical support

Castolin Eutectic welding consumables production

Castolin Eutectic training

Castolin Eutectic local support

Castolininstallation products Eutectic professional

Technical Data welding processes selection

CastoTIG 3011/12 AC/ D C TI G

MMA metal arc weldingProcess Welding manual

PowerMax inverter (liftarc)

CastoMatec Xuper 455

CastoMatec Xuper 455

CastoMatec Xuper 655

TIG Welding Process tungsten inert gas welding

CastoTIG 1501 DC Options

CastoTIG 1701 DC Options

CastoTIG 2201 DC Options

CastoTIG 3011 DC / 3012 AC/DC

CastoTIG 3011 DC CastoTIG 3012 AC/DC Options

CastoTIG 1702 AC/DC and 2202 AC/DC Options

Electronic Wire Feeder

TIG torches selection

Gas cooled Torches

Water cooled Torches

TIG welding torches

Cas toTIG 1501 DC

Plasma cutting Cutting Process plasma arc

MIG/MAG Weldingwelding Process metal inert gas/metal active gas

Accessories for XuperMIG 2500

TIG torches will be changed due to the plug

Accessories for CastoMIG 160C and 250C

Wire feeding rolls

Options/Accessories for CastoMIG 350C/DS

separate Wire Feeder

separate Wire Feeder

Wire Diameter PCS

Drive roll with groove Article

Feedroll with groove Article

Pressure roll smooth Article

Semi circular groove smooth steel teeth Aluminium + cored wire

Trapezoidal groove steel teeth Fe + CrNi

0.8 1.0 1.2 1.6

303433 * 303434 * 302695 303435

302852 * 302852 * 302852 * 302852 *

* Rolls without teeth

4 Rolls system / 2 Rolls system

2) Feedroll with groove 3) Pressure roll smooth 4) Drive gear

Wire Diameter PCS

Feedroll with groove Article

Pressure roll smooth Article

Drive gear Article

Trapezoidal groove steel teeth Fe + CrNi

0.8 1.0 1.2 1.6

302765 302766 302767 302768

302852 * 302852 * 302852 * 302852 *

Semi circular groove knurled steel teeth Cored wire