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Castolin Eutectic
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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
27 28 28 29 29 29 31 32 32 33 33 34 35 36 36 37 37
Technical Data
Welding Processes Selection
Total Arc 4000 (separate wire feeder)(liftarc) Total Arc 5000 (separate wire feeder)(liftarc) Accessories for Total Arc 3000 / 4000 and 5000
2
CastoMatec 305 (liftarc) CastoMatec Xuper 455 CastoMatec Xuper 655 Accessories CastoMatec
PTA Process
Plasma Transferred Arc Process 39 40 40 41 41 42 42 43-44 45 Multi Plasma Module
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
symbols used
EutecTrode
CastoTig
EnDOtec
CastoMag
Three phase
Single phase
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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 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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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
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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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
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
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
CastoMatec Xuper 655
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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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
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
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
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
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
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
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
4 m Article
301715 301238 301279 304120 301153 305000 304986 500264
8 m Article
301719 301241 301282 304121 301156 305001 304990 500265
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
4m
301279 301715 304120 301238 301238 305000 305000 500264
8m
301282 301719 304121 301241 301156 305001 304990 500265
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
Po s s ib l e va ria nt
N o t re co m m e n de d va ria nt
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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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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
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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
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)
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
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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
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MI G /MAG Weld i ng
2 Rolls system
1) Drive roll with groove 2) Feedroll with groove 3) Pressure roll smooth
PCS
1 1 1 1
PCS
-
1 1 1 1
1 1 1 1
PCS
-
PCS
1 1 1 1
21 21 21 21
21 21 21 21
1 302756 1 302756 1 302756 1 302756 * Rolls without teeth 1 1 1 1 1 302756 302756 302756 302756 302756
42 42 42 42 42
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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
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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
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
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MI G pu lse Weld i ng
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
Includes
Operating manual&spare parts list Programs display chart Shielding gas hose, 1.5m 303741 303741 303741 303733 301061 303484
Options / Accessories
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
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MI G pu lse Weld i ng
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
Options / Accessories
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
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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
1.5 m
-
3m
302474
5m
-
CastoMIG 250C
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
* * * w ith wa te rco o li n g
Po s s ib l e va ria nt
n o t re co m m e n de d va ria nt
XuperMig 2500
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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
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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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
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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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
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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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.
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.
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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Cooling GAP *
Technical data
Weight Dimensions L x W x H (mm)) 40 kg 900 x 445 x 360mm 260058
(*) Use only Castolin Eutectic dedicated cooling liquid Single or twin circuit heat exchangers additional water-water heat exchanger available.
260232
260231
RC-H auto
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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
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).
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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 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
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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
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Notes
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Notes
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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
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
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