Thyristor-Controlled Welding Rectifier

OPERATING MANUAL
Printed on paper bleached without chlorine for the protection of our environment.
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Contents Page
General Description 2
Technical Data 2
Safety Precautions 3
Conditions for Setting Up 5
Start-Up 6
Description of Operating Elements 6
Remote Control Operation 7
Manual Metal-Arc Welding 8
Air-Carbon Arc Gouging 8
Circuit Diagram CastoMatec 305 9
Circuit Diagram CastoMatec Xuper 455/655 10
Troubleshooting and Remedial Measures 11
Care and Maintenance 11
Repairs 11
Guarantee 11

General Description
The power sources of the CastoMatec series are sturdy, The unit may only be started up by trained staff under
thyristor-controlled welding rectifiers for welding with acceptable technical conditions.
direct current in the workshop or on site. The manufacturer accepts no liability for damage
which occurs as a result of improper use and opera-
! Current stabilisation:
The welding current set is stabilised by the control tion.
electronics (regardless of the length of welding and It is imperative to read the section on Safety Precau-
mains cables or mains voltage fluctuations). tions and Personal Safety Protection prior to
! Welding current infinitely adjustable by remote start-up.
control.
! The ability to switch over to an intrinsic characteristic The CE symbol attached to the unit refers to the low
ensures the best possible properties when Air
Carbon-Arc gouging with the CastoMatec Xuper 455/ voltage guideline (73/23 EWG).
655.
! Stove-enamelled or powder-coated sheet steel.
! Water-tight electronic casing welded directly onto
basic casing (Faradays cage).
! The large wheels, well-designed transport handles
(fold-down design) and jack rings make it easy to
transport the units both in-house and when used on
site.
! The silicon rectifier assembly is designed as a half-
controlled three-phase bridge connection fitted with
easily replaced screwed diodes and stud-type
thyristors.

Connection
for compressed air

Fig. 1: CastoMatec as Power Source for MMA Welding Fig. 2: CastoMatec as Power Source for Air Carbon-Arc Gouging

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Technical Data CastoMatec 305 Xuper 455 Xuper 655
Unit suitable for welding in areas
with increased electrical hazard: S S S
Mains voltage: 3 x 230/400 V 3 x 230/400/500 V 3 x 230/400/500 V
50 Hz 50 Hz 50 Hz
Mains fuse for 230/400/500 V: 35/20/-- A, 80/50/35 A, 100/63/50 A,
slow-blow slow-blow slow-blow
Apparent power at 100% duty cycle: 8,9 kVA 18,5 kVA 26 kVA
Power factor cos j: 0,66 (150 A) 0,50 (150 A) 0,50 (150 A)
0,88 (300 A) 0,75 (450 A) 0,85 (650 A)
Welding current range: 5 - 300 A 5 - 450 A 5 - 650 A
Welding current at 35 % duty cycle: 300 A 450 A 650 A
at 60 % duty cycle: 230 A 340 A 490 A
at 100 % duty cycle: 180 A 260 A 380 A
Working voltage (Electrode): 20 - 32 V 20 - 38 V 20 - 44 V
Open-circuit voltage: 5V 75 V 75 V
Insulation class: H H H
Protection type: IP 23 IP 23 IP 23
Cooling: F F F
Dimensions L x W x H (mm): 675 x 500 x 450 950 x 740 x 670 950 x 740 x 670
Weight: 95 kg 240 kg 284 kg
Values during gouging Current: -- 520 A 750 A
Voltage: -- 45 V 48 V
Duty Cycle: -- 20 % 20 %

General Safety Regulations Electrical Safety Measures when Arc-welding

! Before opening up any machine, always pull out
the mains plug first, or otherwise ensure that the
machine is "dead".
! Components, assemblies or other units may
only be started up once they have been installed
inside a shockproof housing. They must be
"dead" (i. e. without current) while being in-
stalled.
! Tools may only be used on units, components or
assemblies once it has been ensured that the
units are disconnected from the voltage supply
and that any electrical charges stored in compo-
nents inside the machine have been dis-
charged.
! Live cables or leads connected to units, compo-
nents or assemblies must be checked regularly
for signs of insulation faults or breaks.
If any defect is found in the power supply lead,
the unit must be withdrawn from service imme-
diately, until the defective power lead has been
replaced.
! Where new components and assemblies are fit-
ted, attention must constantly be drawn to the
importance of adhering strictly to the charac-
teristic data for electrical quantities given in the
accompanying descriptions.
If the descriptions provided for the non-indus-
trial final user do not make clear what electrical
characteristic values apply to a component, ad-
vice must be sought from a qualified expert.
Hazards from electric current
Both mains and welding current can be hazardous. It is
forbidden by law for anyone but a qualified electrician to
do anything with any parts which are in contact with
mains voltage. The only exception to this applies, of
course, to the power plug and the mains switch. When
repair or maintenance work is being carried out on the
power source, the machine must first be completely
disconnected from the mains. For all but the most minor
jobs on the machine in the course of which the operator
may have to leave the room, even if only briefly, the plug
socket(s) should be clearly blocked.
Protective earth conductor
Every 3-phase power supply system will have a PE
conductor. This is a non-live, earthed conductor and
connected with the housing of the machine. If an earth
fault occurs on the machine there is an immediate short
circuit between the PE conductor and phase, causing the
fuse on the corresponding phase conductor to blow, and/
or tripping the fault-current breaker (FI).
Both the mains and the machine supply leads should be
regularly checked by a qualified electrician to ensure that
the PE conductor is functioning correctly.
Open-circuit voltage
The highest - and thus the most dangerous - voltage in
the welding current circuit is the open-circuit voltage. The
maximum permissible open-circuit voltages are stipu-
lated in national and international regulations according
to the type of welding current, the design of the current
source and the extent of the specifically electrical danger
posed to the workplace.

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Rectifier power sources
A DC welding power source should be constructed in
such a way that if there is a fault in a rectifier (e.g. open-
circuit, short-circuit or phase fault), the permissible AC-
values cannot be exceeded. Below, the open-circuit
voltage ratings to IEC 974 (1.1.90) for working under
normal conditions and for working under conditions of
increased electrical danger:
Working under normal conditions
For welding jobs done under normal conditions and using
simple equipment, the following open-circuit voltage ra-
tings apply:
! for DC - peak value 113 V
! for AC - peak value 113 V, effective value 80 V
These max. voltages may be exceeded on appliances
equipped with an RC circuit, so long as - with the arc unlit
- the higher voltage does not occur for longer than 0.2
seconds.
Exceptions may apply in the case of fully mechanised,
automatic or other special procedures. For welding cur-
rent sources capable of delivering either DC or AC, the
respective regulations apply to whichever operational
mode the machine is switched to.
Working under conditions of
increased electrical danger
Welding work in confined spaces, in cramped surroun-
dings, on or between electrically conductive parts, in
damp or hot spaces.
For welding jobs done under conditions of increased
electrical danger, the following open-circuit voltage ra-
tings apply:
! for DC - peak value 113 V,
! for AC - peak value 68 V, effective value 48 V.
An AC voltage occurring in the welding circuit may not
exceed 48V. This also applies to welding rectifiers being
used for welding purposes when the equipment is used
e.g. inside a boiler or tank etc. Welding rectifiers for use
inside boilers, tanks and the like must always be clearly
marked with the letter S (safety).
! Solid, insulating footwear should be worn, which
should also insulate the wearer in wet conditions.
Ordinary shoes are not suitable as falling globules
of molten metal can cause burns.
! Suitable clothing must be worn - NO synthetics!
! Do not look at the arc with unprotected eyes. Use
only protective welding shields with the prescribed
type of safety glass. As well as heat and light rays,
which may cause dazzling or burns, the arc also
gives off ultra-violet rays. These are invisible, and if
the welder is insufficiently protected against them
they can cause conjunctivitis, which only makes it-
self felt several hours later and is extremely painful.
Quite apart from this, ultra-violet rays have the
same effect as sunburn on unprotected parts of the
body.
! Welders mates or persons in the immediate vicinity
of the arc must also be made aware of the danger
and provided with the necessary protective appa-
ratus; if necessary, protective screens must be
erected.
! Care must always be taken to provide sufficient
fresh air, especially when welding in enclosed spa-
ces, since smoke and harmful gases are produced
during the welding process.
! Containers which have been used to store gas, fuel,
mineral oils or other such substances must not be
welded, even if they have been standing empty for a
long time, since there is a high risk of explosion from
any residue.
! Special regulations apply to enclosed spaces where
there is a danger of explosion.
! Welds which are exposed to heavy stresses and
which have to fulfil strict safety requirements must
only be performed by particularly well-trained and
experienced welders. Examples include things such
as pressurised containers, track rails, trailer coup-
lings, and so on.

Workpiece clamp
If the electric flex of the workpiece clamp is shorter than L3 (T)
the torch hose pack or the manual electrode cable - N (MP)
PE
meaning that the clamp cannot be fixed anywhere imme-
diately near the welding zone - then the welding current
will find its own way back. It may do this via machine parts
(e.g. during repair work), ball-bearings, electric switches
etc. This may then cause certain parts to become red-
hot, make chains and steel cables snap, and even cause
the PE conductor to melt through.
All this can also happen if the workpiece clamp has
simply not been fastened properly, or only laid on the
surface of the workpiece, in which case the course taken
by the current will depend on the presence of bridges or Fig. 3: Power source may never stand on electrically
conductive ground!
angle bars and the like (Fig. 3) . Connection to workpiece: NEVER like this!
Use a firmly connected clamp.
PE conductors will be destroyed if the welding current
Personal protection ever has to find its own way back.
! As a basic safeguard, insulating gloves should be
worn on both hands when welding. These protect
against electric shocks (from the open-circuit vol-
tage of the welding current circuit), harmful rays
(heat and ultra-violet rays), and against splashes of
red-hot metal or slag.

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Conditions for Setting Up
Open-Air Operation
The unit may be set up and operated in the open in line
with its type of protection IP23 (see Technical Data).
However, the built-in electrical components must be
protected against the effects of direct moisture, e.g. wet
cleaning of the exterior.
Cooling Air and Dust
The unit must be set up so that cooling air can pass
unimpeded through the air vents on the front and escape
through the rear wall.
Dust
Care must be taken that any metallic dust occurring
during grinding, for example, is not sucked directly into
the unit by the fan.

Start-Up
Operator intervention in the electrics such as recon-
nection to a different mains voltage and replacement
or changing of the mains plug may only be per-
formed by a qualified electrician.
The CastoMatec 305 power source may be operated as
standard with a mains voltage of 3 x 230/400 V.
The unit is connected to 400 V ex works. This means
that it is also possible to operate the unit on the 3 x 380
V mains conditional on a tolerance range.
Units which are connected for a voltage other than 3 x
400 V will be identified with a sticker:
CAUTION! UNIT IS CONNECTED FOR ......... V!

The CastoMatec Xuper 455/655 power sources may be If the unit is designed for a special voltage, the
operated as standard with a mains voltage of 3 x 230/400/ technical data on the units rating plate is applicable!
500 V as long as the transformer inside the unit is
connected to the correct value for the operating voltage Mains plugs must correspond to the welding units
applied (Figs. 4 and 5). low voltage and current consumption (see Technical
Data!).
! Green/yellow conductor = protective earth conductor
(PE).
The fuse protection of the mains supply line shall be
Other conductors L1, L2, L3 are connected to the three
designed to correspond with the welding units cur-
phases of the mains plug.
rent consumption.
The phase sequence need not be observed.
!Mains voltage is defined throughout Europe as 400 V
since the introduction of European Standard IEC 38
(valid from May 1987).

230 V 3~ 400 V 3~ 230V 3~ 400V 3~ 500V 3~

L1 L1
L2 L2
L3 L3

L1
L1 L2 L3 L1 L2 L3 L2
L3
Fig. 4: View from the Top: Fig. 5: View from the left-hand side:
Welding Transformer reconnection/terminal plate for Terminal plate for system slection
system selection 3 x 230/400 V for CastoMatec 305 3 x 230/400/500 V for CastoMatec Xuper 455 und 655

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Description of Operating Elements

Fig. 6: Operator's panel CastoMatec Xuper 455 und 655

Main Power Switch ON/OFF ANTISTICK Setting

Ready for Operation Display
lights up when the mains power switch is switched
from "0" to "1".
Welding Current Controller
Outer dial: stepless adjustment of welding current
depending on type of unit from
5 - 300 A, 5 - 450 A or 5 - 650 A.
The inner dial from 0 - 10 serves as an aid to
identifying the welding current during remote control
operation. The remote control units also have a dial
with divisions from 1 - 10. As a result they may be used
with all the units of the CastoMatec series.
Selector Switch / ! The desired current intensity is set using the
(only CastoMatec Xuper 455 and 655)
Setting
! Used for Manual Metal-Arc or TIG welding
= constant current characteristic "CC"
Setting
! Used for gouging and
! when welding flux-cored wires
= drooping characteristic
= Constant current characteristic with automatic
current trip on short-circuit.
If the welding voltage drops below 15 V, e.g. when
the electrode sticks to the workpiece (short-cir-
cuit), the welding current is automatically reduced
to a minimum. The electrode can easily be de-
tached from the workpiece in this situation without
burning out or the coating being damaged (ex-
tremely beneficial when used in training situa-
tions). The full striking voltage is reapplied once
the electrode has been detached.
Selector Switch
for setting welding current INTERNAL - EXTERNAL.
INTERNAL, Setting far right
welding current controller on the welding unit.
EXTERNAL, Setting far left
! The desired current intensity is set using the
remote control unit FR 3-1.

Selector Switch STANDARD/ANTISTICK

(only CastoMatec Xuper 455 and 655)
STANDARD Setting
= Constant current characteristic.
When welding, e.g. with basic electrodes, the
short-circuit current intensity increases only
slightly at the moment of droplet transfer. On
"sticking of the electrode to the workpiece" (short-
circuit) the current increases to the nominal cur-
rent (value of welding current set on dial), the
electrode overheats and can be rendered unus-
able. Fig. 7: Operator's panel CastoMatec 305

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 Connection Jack for Remote Control Unit ! Aim for harder arc for filler welds. These symptoms
Remote Control Operation: Insert the connector of the occur less with fine droplet electrodes (TI) as the
remote control cable and lock into position with the transfer of metal during welding takes place almost
union nut. free of dip.
! Increased spatter in some cases.
Digital Ammeter (Optional)
Serves to display the actual value of the welding
current.

Dynamics Controller (only CastoMatec 305)

Affects the short-circuit intensity at the moment of
droplet transfer electrode/workpiece.
Remote Control Operation
A remote control system is useful wherever it is neces-
V sary to set the welding parameters from the workplace
itself. The remote control unit is connected to the power
50
source electrically by way of special remote control
40 cables 10 m, 20 m or 30 m long. Electrical isolation of
casing and control assembly ensures protection for the
30 electronics in the event of any damage to the remote
control cable.
20

10
5
Remote Control Unit FR 3 -1
Sturdy hand-held remote control unit for the workplace
50 100 150 200 A attached to the workpiece or welding bench by means of
Dynamics a permanent magnet mounted on the back.
0 5 10 Controller Controller is used for stepless adjustment of the
welding current from MIN - MAX.

Fig. 8: Influencing the constant current characteristic using the

Dynamics Controller at the moment of short-circuiting.
Set welding current: 100 A

When the dial is on "0"

the short-circuit intensity at the moment of droplet
transfer increases only slightly (soft arc).
Applications:
! TIG welding.
! Rutile electrodes (fine droplet).
Caution:
Basic electrodes tend to "stick to the workpiece" if
they are welded at low amperage.

When the dial is on "10"

the short-circuit intensity at the moment of droplet
transfer increases by up to 80 A (hard arc).
Applications: Fig. 9
! Basic electrodes (coarse droplet) even if they are
welded at low amperage (vertical-up weld, hard- Connection of Remote Control Unit
facing of edges, roots, etc.) ! Link connection jack of power source and jack of
remote control unit electrically and mechanically us-
Practical Notes ing remote control cable.
The following characteristics are produced with basic ! Plug connectors right sides together and screw up to
or special electrodes as the set values on the Dynam- limit.
ics Controller are increased:
! Switch selector switch to on control panel.
! Good striking behaviour.
! Decrease in welding interruptions.
! Low incidence of sticking.
! Good root fusion in narrow-gap welding
(driving arc).
! The risk of burn-through increases with sheet
metal welding.

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Manual Metal-Arc Welding Air Carbon-Arc Gouging
is used wherever worm-holes, pores or slag inclusions
are to be removed.
Air Carbon-Arc gouging is also used in foundries, for
example, for removing sprues and risers or fettling
(cleaning) of the entire surface of workpieces.
Air Carbon-Arc gouging may also be used for edge pre-
paration of metal plates in welding shops.
! Insert current connection cable of gouging torch into
units positive current jack and lock into place by
turning clockwise (cable cross-section at least 70
mm2).
! Couple gouging torchs compressed air connection to
compressor. Take care to maintain a constant air
pressure of 5 to 7 bar.
! Insert welding return cable into units negative current
jack and lock into place.
Fig. 10: CastoMatec 305, ! Make connection to workpiece (ensure good con-
fitted with manual electrode and welding return cable. tact).
Start-Up Procedure ! Clamp carbon electrode in place so that the distance
! Plug manual electrode and welding return cable into to the electrode tip is approx. 100 mm.
current jacks according to electrode type (observe Also make sure that the gouging torchs air outlet
electrode manufacturers information) and lock into holes are facing downwards.
position by turning in a clockwise direction. ! Plug in mains plug.
! Plug in mains supply plug. ! Switch mains switch from 0 to 1.
! Switch mains supply switch from "0" to "1". ! Green pilot light indicates the units readiness for
! Green pilot light indicates the units readiness for operation.
operation. ! Units cooling fan starts up.
! Cooling fan starts up. (check that air outlet on back is not obstructed).
! Switch selector switch to ! Turn selector switch to position (only
(only CastoMatec Xuper 455/655) or set Dynamics CastoMatec Xuper 455/655).
Controller (only CastoMatec 305).
! Set current intensity internally or externally in accor-
! Switch selector switch to STANDARD or ANTI- dance with Table 2.
STICK position as required (only CastoMatec Xuper
! Open compressed air valve on handle of gouging
455/655).
torch (the flow rate may be adjusted at this point) and
! Set selector switch to INTERNAL when welding initiate gouging process.
without remote control unit.
! The depth of groove is determined by the inclination
! Connect remote control cable to position when angle of the carbon electrode and by changing the
using remote control (selector switch on EXTER- gouging speed.
NAL).
! At high current intensities the gouging torch should be
! Initiate welding procedure. operated using both hands (wear protective helmet).
! Use protective ear muffs.
Set values
Table 1 illustrates the permissible current loading limits
for the most important electrode diameters and rules of
thumb for their calculation. The values shown are only
valid for unalloyed and low-alloy coated rods and the
specified electrode lengths.

Electr. mm 2.0 2.5 3.25 4.0 5.0 6.0

Electr. (mm) 4 5 6 8 10
Length mm 250 / 300 350 350 / 450 350 / 450 450 450
Amps. MIN 80 110 150 200 300
Current
40 - 80 50 - 100 90 - 150 120 - 200 180 - 270 220 - 360
Intensity A Amps. MAX 150 200 400 450 600
Rule-of-thumb
min. 20 x min. 30 x min. 35 x Table 2: Current Intensities for Gouging
for current
max. 40 x max. 50 x max. 60 x
intensity

Table 1: Current Intensities as a Function of Electrode Diameter

8
Circuit Diagram CastoMatec 305

9
Circuit Diagram CastoMatec Xuper 455/655

10
Troubleshooting and Remedial Measures
CAUTION: Unit may only be opened by qualified technicians!

FAULT CAUSE REMEDY

1. NO WELDING CURRENT Unit overloaded. Check fan.

Mains switch switched on. Thermostat has cut out. Let unit cool down.
Green pilot light lights up. (Remember duty cycle).
No connection to workpiece. Check earth connection.
Defective thermal cut-out. Replace thermal cut-out.
Faulty electronics. Replace plug-in module.

2. WELDING CURRENT Change-over switch "internal/ Select correct position.

CANNOT BE REGULATED external" in incorrect position.
Break in remote control cable. Replace remote control cable.
Remote control unit faulty. Replace remote control unit.
Faulty electronics. Replace plug-in module.

3. MAINS FUSE BLOWS AS SOON Defective power thyristors, power diodes Check or replace thyristors, diodes
AS MACHINE IS SWITCHED ON or transformer and transformer.

4. UNIT CONSTANTLY DELIVERS Shunt connections loose Tighten connections ensuring correct
MAX. WELDING CURRENT (twisted grey and black lead). polarity.

5. POOR WELDING Incorrect polarity of welding electrode. Change polarity

CHARACTERISTIC
(high degree of spatter)
but welding current is
identical to set value on dial.
Incorrect position of selector switch
Incorrect position of mains plug.
Phase down in mains.
Diode or thyristor defective.
Faulty electronics.
(Observe manufacturer's instructions).
. Move switch to correct position.
Check connection of mains plug.
Check mains fuse, mains switch and
mains terminal board if using special
voltages.
Check or replace diodes or thyristors.
Replace electronics.

Care and Maintenance Guarantee

Under normal operating conditions the CastoMatec Units
require a minimum of care and maintenance. However,
to ensure continued trouble-free operation of your machine
for years to come, a certain amount of basic maintenance
must be carried out.
! Check the mains plug and mains cable, and the
welding torch and earth connection, for signs of
damage from time to time.
! Once or twice a year, unscrew the welding machine
casing. Caution: Switch off the machine and pull
out the plug first!
! Clean out the inside of the unit using dry compres-
sed air (be careful - blowing compressed air directly
onto electronic components from too close a
distance may damage them!).
Repairs
Repairs to the equipment may only be carried out by
our service department or by persons authorised by
E+C.
The guarantee period is 12 months and applies to sin-
gle-shift operation, provided that the equipment is used
properly.
The guarantee covers the costs for replacement parts
and component groups including assembly time.
The guarantee does not cover wear and tear of com-
ponents due to operation. Improper use of the equip-
ment including damage caused by force invalidates the
guarantee.
Please forward the serial number of the equipment in
the event of any guarantee claim.
Return of the equipment requires our prior consent.
Transportation and related costs will be at the expense
of the purchaser (please refer to the General Sales
Conditions).

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 Switzerland Great Britain Australia Germany
Castolin S.A. Eutectic Company Ltd. Eutectic Australia Pty. Ltd. Castolin GmbH
Case postale 360 Burnt Meadow Road 9 Mavis Street Gutenbergstrae 10
CH-1001 Lausanne Redditch, Worcs. B98 9NZ Bankstown, N.S.W., 2200 D-65830 Kriftel
Tel. 021 / 6 94 11 11 Tel. 0 15 27 / 51 74 74 Tel. 02 / 771 5000 Tel. 0 61 92 / 4 03 - 0
Fax 021 / 6 94 16 71 Fax 0 15 27 / 51 74 68 Fax 02 / 771 5005 Fax 0 61 92 / 40 33 14

We reserve the right to change specifications in the interest of technical progress without notice. by Eutectic+Castolin - 39294 E - 9047
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