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TeroMatec
Wire Feeder 600

Welding
Operating Manual
Version 1.10.06
from serial no.: 1004005

Operating Manual Page 1 Safety rules

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Operating Manual Page 2 Safety rules

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INTRO

Dear client,
Thank you for selecting a Castolin Eutectic product, designed and manufactured
according to the highest standards.
Quality workmanship and the use of top-grade selected materials will ensure you many
years of trouble free operation.
We wish you every success with this Castolin Eutectic product.

Please read carefully the safety procedures and warnings, to avoid accidents, prevent
injuries or damages and increase the enduring quality and reliability of the equipment,
essential prerequisites for ideal performance and results.

These operating instructions are the intellectual property of the Castolin Eutectic
Group (company) and must not be copied in any form or made available to third parties
without the express approval of Castolin Eutectic.
Any unauthorised use will be prosecuted under civil and criminal law.

CASTOLIN EUTECTIC RESERVES THE RIGHT TO IMPROVE OR MODIFY THIS OPERATING

MANUAL WHENEVER NECESSARY OR RECOMMENDABLE AND WITHOUT PREVIOUS
NOTICE.

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EXPLANATION OF THE PICTOGRAMS AND SYMBOLS

The following table sets out the various danger levels and allocates a symbol,
degree of danger and its signal word to the actual danger and possible
consequences.

DEGREE OF DANGER DAMAGE TO

SYMBOL DEFINITION CONSEQUENCES
Class Signal word Persons Property

Immediate
danger, Death or serious
A Danger! X hazardous injury
situation

Potentially
dangerous, Possibly death or
B Warning! X hazardous serious injury
situation

Less Minor or
C Caution! X dangerous moderate
situation injury

The product or
Possibly
something in its
D Attention! X damaging
surroundings may
situation
be damaged

Note! Not a signal for a

Hints for use
harmful or
E Important! X and useful
dangerous
(Information) information
situation.

Whenever you see any of the symbols shown above, you must pay
even more attention to the contents of the manual.

Warning!
Avoid danger when operating the equipment by
behaving in a safety-conscious way
acting responsibly and prudently
Therefore carefully read and observe the danger notes in these
operating instructions!

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SAFETY

The equipment is manufactured according to the state of the art and general safety
standards. Nevertheless, if the equipment is operated incorrectly or abused, there is
a threat of danger to
the life and limbs of the operator or third parties,
the unit and other valuable property belonging to the operator,
the ability to work efficiently with the unit.

All persons who are involved with start-up, operation, maintenance and repair of the
equipment must
be appropriately qualified,
have a knowledge of welding and
have read these operating instructions in full and follow them to the letter.

The operating instructions and safety rules must always be kept in close proximity to
the place where the equipment is used.
The regulations governing accident prevention and environmental protection that are
applicable in general and pertinent locally must be provided as a supplement to the
operating instructions and must be complied with.

All safety and hazard warning signs on the equipment must

be kept in a legible condition
not be damaged
not be removed
not be covered up, pasted or painted over.

Please consult the section headed General of the operating instructions for your
equipment regarding the positions of the safety and hazard warning signs on the
equipment.
Remedy any faults that might impair the machines safety prior to switching it on.

YOUR SAFETY IS PARAMOUNT!

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INTENDED USE

The equipment may only be used for jobs as defined by the Intended use.

The equipment may only be used for the welding processes stated on
the rating plate.

This equipment is not designed for any use outside or beyond the
stated applications: the manufacturer will not be liable for any damage
arising as a result of such use.

The following are also considered to be part of defined use:

reading in full and following all instructions contained in the operating instructions
reading in full and following all safety and hazard warning instructions
compliance with inspection and maintenance work

Never use the equipment for the following applications:

thawing pipes
charging batteries/accumulators
starting engines
electrochemical processes

The equipment is designed for operation in trade and industry. The

manufacturer will not be liable for damage attributable to use within the
domestic arena.

Likewise Castolin does not accept any liability for defective or faulty
work results.

Warning!
It is essential that these operating instructions are read and
observed prior to operating the equipment!
Not reading can result in dangerous or hazardous situation!
This equipment must be operated only by persons being familiar
with the relevant safety regulations (BGV D1).

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RESPONSIBILITIES OF THE OPERATOR

The operator shall undertake to allow to work on the equipment only to people who
must:
be familiar with the basic regulations governing health and safety and
accident prevention and have been trained in handling of the equipment
have read and understood the chapter headed Safety Regulations and the
warning notes in these operating instructions and confirmed this by their
signature
be trained in accordance with the requirements for the work results.
Checks must be made at regular intervals to ensure that staff works in a safety-
conscious manner.

RESPONSIBILITIES OF THE STAFF

Prior to starting all people who are commissioned to work on the equipment shall
undertake
to comply with the basic regulations for health and safety and accident
prevention
to read the section headed Safety Regulations and the warning notes in
these operating instructions and to confirm by their signature that they have
understood and will comply with them.
Ensure prior to leaving the workplace that no damage can occur to people or
property even in their absence.

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GENERAL SAFETY NOTES

THE FOLLOWING MEASURES FOR SAFE OPERATING OF THE

EQUIPMENT
DEPEND ALSO ON A SAFETY-CONSCIOUS APPROACH TO WORK!

Prior to installation and use of the equipment, carefully read and observe the
notes in the operating instructions.

The operating instructions must be readily accessible at all times where the
equipment is operated!
Avoid:

burn injuries & damage arc radiation
always wear appropriate protective clothing, welding gloves, work shoes and
protective goggles.

toxic fumes
by providing a suitable supply of fresh air and evacuation of fumes

fire and explosions
by avoiding welding work in areas containing easily flammable materials or where
the air contains ignitable dust, gas or vapour.
Likewise Castolin does not accept any liability for defective or faulty work results.

Do not weld in areas where there is a potential for fire and explosion or in closed
tanks, casks or pipes unless they have been prepared in line with the appropriate
national and international standards.
Always keep your equipment clean!
Never leave the equipment switched-on and unattended!
Never remove or deactivate safety devices!
Any necessary repair or maintenance work to the equipment, welding torch or
connected accessory must only be carried out

with the power supply switched off and disconnected from the power
point (mains supply)

by appropriately trained and qualified personnel
Equipment must be connected only in correctly earthed sockets.
Operation of the equipment on a mains network without protective earth, neutral
wire and using a socket without a protective earth contact and neutral contact is
considered to be grossly negligent. The manufacturer will not be liable for any
damage caused as a result of this.
Cable and plug of the main supply should be regularly checked. Only qualified
personnel should solve or repair defects and replace parts.
Before opening the chassis disconnect the power plug from the mains and wait
at least 2 minutes until all capacitors are discharged.
Do not touch any live parts, either inside or outside the equipment.
In MIG/MAG welding, the welding wire, the wire spool, the drive rollers and all
metal parts having contact with the welding wire are also live.

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Never immerse the welding electrode (rod electrode, tungsten electrode, welding
wire, ...) in liquid in order to cool it, and never touch it when the power source is
ON.
All cables must be solid, undamaged, insulated and adequately dimensioned.
Replace loose connections, scorched, damaged or under-dimensioned cables
and wires immediately.
Have the mains and equipment supply cable checked regularly by a specialist
electrician for proper function of the protective earth.

Danger!
Any repair or maintenance work to the equipment must only be
carried out with the power supply disconnected!

Warning!
Switch off the main switch of equipment before changing spare
parts on the equipment, torch or connected accessory.

Warning!
Any kind of mechanical or electrical modifications of the
equipment must be carried out only after obtaining approval from
Castolin Eutectic!
The equipment must only be operated with the protective devices
provided by the manufacturer!

Appropriately trained and qualified personnel

Means personnel authorised to use the equipment, as a result of a complete
training, experience and qualifications, as well as their knowledge of relevant
standards, regulations and accident prevention measures.
Only these persons are in the position of carrying out the required tasks while
recognising and avoiding potential dangers.

WARNING AND DANGER NOTES

Always ensure that nobody without suitable protections is present in the welding
area and danger zone of the equipment! If there are still any other persons
nearby during welding, you must:

draw their attention to all the dangers,

provide them with suitable protective equipment and/or

erect suitable protective partitions or curtains.
Protection from burns:

Protecting the hands with appropriate gauntlets (insulating against electricity
and providing protection against heat),

Protective clothing must be non-flammable, free from damage and in good
condition.

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Protection from flying sparks:

Never perform welding anywhere near combustible materials. Combustible
materials must be at least 11 meters (35 feet) away from the arc, or else must be
covered with approved coverings.

Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that there is
no risk of injury or fire

Have a suitable, approved fire extinguisher at the ready.
Eye protection from radiant energy and foreign objects:

Using a protective shield with regulation filter to protect eyes and face against
UV radiation, heat and flying sparks.

Point out potential dangers to all personnel and people nearby, and equip
them with suitable protection parts.
Protection of the skin against ultraviolet rays

Welding arcs generate ultraviolet rays, therefore protect the skin from
radiations.
Protection from electric shocks:

Use sturdy shoes that provide insulation even in wet conditions.

Keep clothing and body dry.
Protection from poisonings:

Welding operations produce harmful gases, install suitable fumes extraction
equipment and continuously supply fresh air.

Welding fumes contain substances that may cause birth defects and cancer.
Turn the head away from any welding fume and gases arising.

Wear breathing mask with air supply if ventilation is inadequate.

Compare the measured emission values for pollutants with the permissible
threshold values if there is any uncertainty as to whether the extraction capacity
is sufficient.

The following components, amongst other things, are responsible for the
welding fumes degree of toxicity:
- metals used for the work piece
- filler metal
- coatings
- cleaners, degreasers and the like
It is necessary, therefore, to take into account the appropriate material safety
data sheets and the manufacturers information regarding the components listed
above.

Keep flammable vapours (e.g. solvent vapours) away from the arcs radiation
area.
wear hearing protection to reduce noise pollution and protect against
injury.

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WARNING SIGNS ON THE MACHINE

Extra warning labels are fixed to the machine.

The warning labels must not be removed or painted over.
The symbols warn against incorrect operation.
Incorrect operation can cause serious personal injury and damage to property..

Danger! Read operating instruction

Before starting the equipment and its applications pay
attention to manual.

Harmful electromagnetic fields which may put the lives of

cardiac pacemaker users at risk.

Machines with this warning signs are not allowed to

operate on grounded phase conductors.

MEASURES CONCERNING THE MAGNETIC FIELD

The operating power source generates a strong magnetic field.

The operators area of responsibility includes ensuring that no electromagnetic
interference occurs in electrical and electronic equipment.
The operator must immediately take countermeasures to remedy the problem if
electromagnetic interference is discovered.

Attention!
In close proximity of the operating power source
Do not store electronic media such as for example magnetic tapes,
diskettes, audio or video cassettes, magnetic cards etc.,
Do not use electromechanical equipment such as for example
watches, TV sets etc.

Electromagnetic fields can cause health damages that are unknown as yet.
Supporting Measures to Prevent EMC Problems:
a) Mains supply

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- implement extra measures (e.g. use suitable mains filter) if electromagnetic
interference occurs despite connection to the mains according to regulations.
b) Welding cables
- keep them as short as possible
- have them run close together
- lay them well away from other cables
c) Equipotential bonding
d) Earthing of the work piece
- create earth connection via appropriate capacitors if necessary.
e) Shielding, if necessary
- shield other equipment in the surrounding area
- shield the entire welding installation

Danger!
Persons who are wearing electrical medical devices (cardiac
pacemakers, ) must not use the power source!
magnetic fields caused by high voltage may interfere with
the operation of cardiac pacemakers, etc.!

Operators workplace
In spite of limit value compliance with VE E8850, the following precautions should
be taken to reduce magnetic flux density at the operator's workplace:

Do not route cables or wires in close proximity to the genital area (if necessary
attach them to the work bench).

Do not loop cables or wires around the body or parts of the body.

PARTICULAR DANGER POINTS

Keep hands, hair, items of clothing and tools well away from moving parts such as:
- fans
- toothed wheels
- rollers
- shafts
- wire coils and welding wires

Do not intervene in rotating toothed wheels of the drive or rotating drive parts.
During operation ensure that all covers are closed and all side panels are properly
assembled and keep closed.
When the welding wire emerges from the torch or the wire feeder, there is a high
risk of injury (the wire may pierce the welders hand, injure his face and eyes ).
Do not touch the work piece during and after welding risk of burns.

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Allow welding torches and equipment parts with high operating temperatures to cool
down before any work is carried out on them.
Risk of scalding due to escaping coolant: switch off the cooling unit prior to
removing connectors for the cooling liquid.

Warning!
The equipment must only be operated with the protective devices
provided by the manufacturer firmly in place!
The equipment housing cover must be removed by authorised
personnel only!

DANGER DUE TO GAS CYLINDERS

Gas cylinders contain gas under pressure and may explode if damaged.
Gas cylinders must be handled very carefully as they are a component part of the
welding equipment.
Protect gas cylinders from excessive heat, mechanical impacts, slag, open flames,
sparks and arcs.
Install the gas cylinders vertically and secure in place according to the instructions
so that they cannot fall over.
Keep gas cylinders well away from welding or other electrical circuits.
Never hang a welding torch over a gas cylinder.
Explosion risk never weld on a gas cylinder that is pressurised.
Only ever use gas cylinders and accessories (regulators, hoses and fittings, etc.)
that are appropriate to the application in each case. Only use gas cylinders and
accessories that are in good condition.
Turn the face away from the outlet if the valve on a gas cylinder is opened.
Close the gas cylinder when welding is not taking place.
Leave-place the cap on the valve of the gas cylinder when the cylinder is not
connected.
Comply with the manufacturers instructions and corresponding national and
international specifications for shielding gas cylinders and accessories.

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DELIVERY AND TRANSPORT

As soon as you are delivered the equipment, please check that any individual item
in the packing list is included in the shipment and that no individual part was
damaged during the transport.
In case of any shortcomings please contact your supplier immediately.

Instructions for transport

Care must be taken when transporting the equipment, in particular when lifting,
lowering and placing the equipment, shocks must be avoided.

When transporting the equipment, ensure that applicable national and regional
guidelines and accident prevention regulations are complied with.
This applies in particular to guidelines governing hazards during transport and
shipment.

Dismantle the following components prior to every transport:

- wire / power feed unit
- wire coil
- gas cylinder(s)

It is imperative that a visual inspection of the equipment is performed to check for

any damage prior to starting up after transport. Have any damage repaired by
Castolin Eutectic trained service staff prior to starting up.

STORAGE

If you are not planning to use the equipment for a long period of time, store it in a
dry and dust-free place.
When moving the equipment in between environments with different conditions in
terms of temperature and humidity, moisten might condensate inside the equipment
and its electronic components.
In these conditions the use of the equipment might lead to short circuits and other
damages of the electronic system.

Attention!
In case of moisten condensation, leave the equipment in a warm
location for at least one hour to enable condensation to
evaporate.
Only then connect the equipment to the mains supply.

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PLACE OF OPERATION

The equipment must be operated in a clean, dust-free place!

An equipment that falls over may cause fatal injury! Set the unit up so that it stands
steadily on a levelled and solid base.
If using the equipment with a trolley, additional care must be taken to ensure that the
trolley is secured against rolling away unintentionally. The angle of inclination must
not exceed 10.

Make sure that the equipment is always clearly visible during operation. This is a
prerequisite for proper and safe operation of the equipment.

Special rules apply in rooms exposed to fire and explosion hazards observe
corresponding national and international regulations.

The equipment may only be set up and operated in accordance with the class of
protection specified on the rating plate.

Ensure that there is a clear space of 0.5 m (1.6 ft) around the equipment when
setting it up so that cooling air can enter and escape unimpeded.

Ensure the ground clamp is securely connected to the work piece itself.
Attach the ground clamp as near as possible to the area to be welded.
Set up the equipment with adequate insulation to the ground in the case of
electrically conductive floors.

EMERGENCY

In case of emergency switch equipment off and disconnect the electricity supply and
gas supply immediately.

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SAFETY PRECAUTIONS IN NORMAL OPERATION

Only operate the equipment if all of its protective features are fully functional.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered by your
doing so.

Attention!
The equipment must only be operated by appropriately trained
and qualified personnel!

Caution!
Before activating any switch, make sure that nobody is
endangered as a result!

Workpiece clamp
If the electric flex of the workpiece clamp is shorter than the torch hose pack or
the manual electrode cable meaning that the clamp cannot be fixed anywhere
immediately near the welding zone then the welding current will find its own
way back. It may do this via machine parts, 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 angle bars and
the like.

MAINTENANCE

Regular and careful maintenance of the equipment and its accessories provides the
best conditions for longevity of the equipment and quality of the welding.

Observe the following basic rules carefully:

 Disconnect the equipment from the mains supply
 Clean the equipment after use
 Do not use solvents to clean the equipment
 Never use compressed air to clean the equipment
 Check tubes, hoses and connecting lines and cables for defects, failures
and leakages, and if necessary have it replaced/repaired by qualified
personnel.

Attention!
Only appropriately trained and qualified personnel must be
authorised to:
carry out maintenance tasks
remove and install protective devices and covers
The housing cover may only be removed by authorised and
trained personnel.

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Warning!
Before carrying out any maintenance work on the equipment:
Switch off main switch
Disconnect the power supply cable
Display an easy-to-understand warning sign to prevent
anybody from inadvertently switching it on again
Allow at least two minutes for all capacitors to discharge.
Using a suitable measuring instrument, check to make sure
that electrically charged components (e.g. capacitors) have
been discharged

The directions and recommendations provided for operating and maintaining the
equipment do not release the operator from the obligation to carefully monitor the
equipment and immediately report any malfunction.
The manufacturer does not accept any warranty claim for damages as a
consequence of improper maintenance or incorrect operation of the equipment.
There is no guarantee in the case of parts obtained from other manufacturers even if
designed and produced in line with stress and safety requirements.
Use only original spare and wear parts (also applies to standardised parts).
Replace components that are not in perfect condition immediately.

Before every start-up:

Before commissioning a visual check for damage must be carried out. Any
damage must be repaired by trained service personnel before
commissioning.
Check equipment, mains plug, mains cable, welding torch, connected
accessory, interconnecting hose pack and earth connection for damage
Check that there is a gap of at least 0.5m all around the machine to ensure
that cooling air can flow and escape freely.

Attention!
Air inlets and outlets must never be covered, not even partially.

Every 6 months:
Dismantle machine side panels and clean machine interior with dry reduced
compressed air.
If there is a heavy accumulation of dust, clean the cooling-air ducts as well.

Attention!
Risk of damage to electronic components, do not drive the
compressed air nozzle too close to the electric components.

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SAFETY INSPECTION

The operator must have a safety inspection carried out on the unit at least every 12
months.
A complete safety inspection must be carried out by a certified specialist electrician
- including and following modifications (when applicable)
- including and following installations or conversions (when applicable)
- following repairs, servicing and maintenance
- at least every twelve months.

Observe the appropriate national and international standards and guidelines for the
safety inspection.
Additional detailed information regarding safety inspections may be obtained from
your Castolin Eutectic service centre. This centre will provide you with the necessary
documents, standards and guidelines on request.

DISPOSAL

The equipment is made of various materials.

Recycle metals and plastics.
Dispose of electronics components as special waste.

Note!
Carefully observe the environmental protection laws applicable
in your country!

DATA SECURITY

The user is responsible for the data security of changes made of factory settings.
Castolin Eutectic is not liable, if personal settings are deleted.

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SAFETY MARKINGS

Equipment with CE-markings fulfils the basic requirements of the Low-Voltage and
Electromagnetic Compatibility Guideline.
EC low-voltage directive (2006/95/EEC)
EC- EMV- directive (2004/108/EEC)
(( - mark is necessary and required only within the EC members)

Equipment marked with the S symbol and can be used in increased electrical
danger environments in accordance with EN 60974-1.

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F660
000 From Serial No
WSN 1004005

TABLE OF CONTENTS

1.0 GENERAL 22
1.1 TEROMATEC - ELECTRODE CONCEPT 22
1.2 TEROMATEC WIRE FEEDER 600 23
1.3 DEPOSITION RATE 24
1.4 PARAMETER SETTING 24

2.0 GENERAL NOTES 25

2.1 WARRANTY AND LIABILITY PROVISIONS 25
2.2 WARRANTY 25
2.3 INTENDED USE 26

3.0 RATING PLATE 27

3.1 RATING PLATE: TEROMATEC WF 600 27

4.0 TECHNICAL SPECIFICATIONS 28

4.1 TEROMATEC WIRE FEEDER 600 28
4.2 ENVIRONMENTAL CONDITIONS 29

5.0 DESIGN AND FUNCTIONS 30

5.1 CONSTRUCTION 30
5.1.1 TEROMATEC WF 600 - FRONT 30
5.1.2 TEROMATEC WF 600 REAR SIDE 31
5.1.3 TEROMATEC WF 600 SIDE VIEW 32
5.2 SYMBOLS DESCRIPTION 33
5.3 COOLING (OPTION) 34

6.0 BEFORE START UP / INSTALLATION 35

6.1 GENERAL DETAILS 35
6.2 ELECTRICAL INSTALLATION 35
6.3 CONNECTION SCHEME 35
6.4 CONNECTING THE TEROMATEC WF 600 TO THE POWER SOURCE AND THE WORKPIECE 36
6.5 CONNECTING THE WELDING TORCH TO THE TEROMATEC WF 600 37
6.6 MOUNTING THE WIRE-SPOOL 38
6.7 FEEDING IN THE WIRE ELECTRODE 39
6.8 CHANGING THE FEED ROLLERS 40

7.0 START-UP 41
7.1 START UP 41
7.2 WELDING TORCH OPERATING MODE (STEP MODE) 42
7.2.1 EXPLANATION STEP - MODE 42
7.2.2 2-STEP 42
7.2.3 4- STEP 42
7.3 WELDING PROCEDURE 43
7.3.1 ARC VOLTAGE EFFECTS 43
7.3.2 ARC CURRENT EFFECTS 43
7.3.3 TORCH TRAVEL SPEED EFFECTS 43

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8.0 TROUBLESHOOTING 44
8.1 GENERAL NOTES 44
8.2 POSSIBLE MALFUNCTIONS, CAUSES AND CORRECTIVE ACTION 44

9.0 APPENDIX 45
9.1 INTERFACE -1X1 (TORCH) 45
9.1.1 CONFIGURATION 45
9.1.2 PLUG ALLOCATION -1X1 45
9.1.3 PLUG -1X1 45
9.2 MAIN DIMENSIONS TEROMATEC WIRE FEEDER 600 46
9.3 OPTIONS / ACCESSORIES 47

10.0 PRODUCT MONITORING 48

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1.0 GENERAL

The TeroMatec process is a semiautomatic system for wear protection and joining
technology without shielding gas. A wide variety of wear-resistant and high quality
welding alloys are available.

Next to fully automatic welding processes, the TeroMatec process is easily one of
the fastest welding methods used by industry today. It is much faster and more
efficient than stick electrodes.

1.1 TeroMatec - Electrode concept

The continuous electrodes for the TeroMatec Wire Feeder are developed for
outdoor maintenance and repair without need for protective gases or fluxes.
In contrast with the solid wire used in MIG/MAG processes, the TeroMatec cored
electrode consists of an outer metallic sheath packed with special alloy micro-
particles.
Flux cored welding wires, widest range of alloys means for you composite
wearfaced surfaces with maximum abrasion resistant alloys, fastest cost-effective
deposition rates for on-site works.
Solidified slag Wire guide / contact tube
Molten slag
Cored wire

Particles-elements/compounds

Gas shield created by compounds

Arc and metal transfer

Solidified weld metal

Weld pool

Fig. 1.1.a: TeroMatec Process

The continuous electrode concept is the reverse of the coated manual electrode:
The internal part of one being the external part of the other.
Cross-sections:

Manual electrode - MMA TeroMatec continuous

cored electrode

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1.2 TeroMatec Wire Feeder 600

The TeroMatec Wire Feeder 600 is designed for coating and joining with open-arc
wires in the field. Connected directly to the arc voltage. No mains connection is
needed. It operates with any drooping characteristic welding power source (AC of
DC)*.
The TeroMatec Wire Feeder 600 is easier to use than a manual electrode as a
constant arc length is assured by self regulation of the variable wire speed. Any arc
length changes are automatically compensated via the arc voltage driving the wire
speed. This feature is unique to TeroMatec Wire Feeder 600.
The equipment is easy to operate. Wire feeding starts when the arc is struck and
stops whenever the arc is interrupted.

* Suitable are CE marked welding power sources or those with OAV < 113V.

TeroMatec
Continuous electrode Wire Feeder 600

Contact nozzle
+
Power source
Motor

-
Voltage measuring line
Workpiece

Fig. 1.2.a: The electric circuit the arc

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1.3 Deposition rate

One of the reasons why TeroMatec electrodes deliver more deposited metal per
pound than conventional stick electrodes is the fact that there is more metal per inch
of electrode.

TeroMatec 2,8mm
Deposition rate [kg/h]

stick-out:75mm

TeroMatec 2,8mm
stick-out: 50mm

TeroMatec 1,6mm
MMA, 5mm

Strom [A]
Fig. 1.3.a: Deposition rate

Stick-out:
The stick-out distance is the distance between the contact nozzle and the tip of the
continuous electrode.
A longer stick-out distance increases the electrical resistance between the contact
nozzle and the electrode tip. The electrode then heats up and the deposition rate
rises.

1.4 Parameter setting

The voltage varies with the arc length.
for example: current adjusting 300A
Spannung

A
200 300 500
Fig. 1.4.a: Parameter setting

The current setting for any electrode diameter influences the fusion rate (deposition
rate) and the penetration.
The voltage varies with the arc length:
- long arc: higher voltage
- short arc: low voltage

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2.0 GENERAL NOTES

2.1 Warranty and liability provisions

The manufacturer provides a warranty of 12 months from the date of delivery and is
valid providing the apparatus is used only for appropriate applications and by a
maximum of one shift a day.
The warranty expressly excludes wear parts such as for example wire electrodes,
cable and hose assembly, welding torch, cable, ... etc., and any damage resulting
from operator errors or negligent use of the power source as well as any damage
caused by external influences on the power supply, lightning strike, act of God etc.
Any inappropriate use of the equipment, negligence in following operating and
safety instructions, unauthorised mechanical or electrical modifications of the
equipment and the use of non original parts, render the warranty null and void!
The manufacturer is not liable for any consequential damage arising from improper
use or from the use of our product contrary to its intended use.
At the same time this will render null and void any claim for compensation under the
provisions of the product liability law in the case of personal injury or property
damage whether the parties be involved directly or indirectly.
Furthermore, any claims for compensation, in particular economic loss or
consequential loss between the manufacturer and other industrial enterprises is
excluded.

Operating instructions
Great care was taken in the preparation of the operating instructions. However we
cannot guarantee that they are free of any errors.

Elements and parts sourced from external suppliers

All elements and parts sourced from external suppliers were installed according to
the manufacturers installation guidelines.

2.2 Warranty
We assume the fact that you have checked the suitability of this equipment for the
intended use, because we must expel in this respect a warranty. As well we can
take over no warranty for the success of the works to be executed from you.
The warranty covers the machine for defects in materials and workmanship.
The warranty DOES NOT COVER:
parts subjected to wear during the use of the equipment
damages deriving from inappropriate use or use outside the intended ones.
Any claim of an apparatus requires Castolin+Eutectic prior agreement.
Transportation and related costs will be at the expense of the purchaser.
Our standard warranty conditions apply.

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2.3 Intended use

The device is meant to be used exclusively for wire feeding in combination with
a power source as described below.

The designed application includes the following:

welding in combination with an external power source
device operates with
any drooping characteristic welding power source (AC or DC)*
developed specially for heavy duty wear protection applications
Designed for coating and joining with open-arc wires

* Suitable are CE marked welding power sources or those with OAV < 113V.

This equipment is not designed for any use outside or beyond the
stated applications: the manufacturer will not be liable for any damage
arising as a result of such use.

The following are also considered to be part of defined use:

reading in full and following all instructions contained in the operating instructions
reading in full and following all safety and hazard warning instructions
compliance with inspection and maintenance work

The unit is designed for operation in trade and industry. The

manufacturer will not be liable for damage attributable to use within the
domestic arena.

Likewise Castolin does not accept any liability for defective or faulty
work results.

WARNING!
It is essential that these operating instructions are read and
observed prior to operating the equipment!
Not reading can result in dangerous or hazardous situation!
This unit must be operated only by persons being familiar with
the relevant safety regulations (BGV D1)!

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3.0 RATING PLATE

3.1 Rating plate: TeroMatec WF 600

Erklrung:

TeroMatec WF 600 DEVICE TYPE

IEC 60974-5 The device complies with requisites and demands of the
listed norms.
WSN Serial number (commission number) of the device
Equipment with CE-markings fulfils the basic
requirements of the Low-Voltage and Electromagnetic
Compatibility Guideline.
Application of this symbol on your equipment is
confirmation that you must dispose of this equipment in
compliance with agreed national procedures.
In accordance with European legislation, end of life
electrical and electronic equipment subject to disposal
must be managed within agreed procedures.
U1 Rated value of the power supply voltage in V
I1 Rated value of the power supply current in A for feeder
motor and control components
I1 max Maximum rated value of the power supply current in A
for feeder motor and control components (fuse)
I2 Rated value of the welding current in A with related duty
cycle in %
IP 21 S Protection class

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4.0 TECHNICAL SPECIFICATIONS

4.1 TeroMatec Wire Feeder 600

ELECTRICITY
max. welding current (100% d.c.): 400 A
max. welding current (35% d.c.): 600 A
Welding current: AC or DC
Rated value of the power supply voltage max. 113V
(Welding power source open circuit voltage):
Motor voltage: max. 24 V
Type of protection: IP 21S
WIRE
Types of wire-spool: All standard wire-spools
Adapted for wire-spools and rings: Wire-spools: max. 15 kg
Rings: max. 25 kg
Wire-spool diameter: 300 mm
DRIVE
Drive: 4 roller drive
Wire diameter: 1,6; 2,0; 2,4; 2,8; 3,2 mm
NOISE
Continuous sound-pressure level: < 70 dB (A)
DIMENSIONS
Length: 715 mm (28.2 inch)
Width: 265 mm (10.5 inch)
Height: 380 mm (15.0 inch)
Total weight (without cables / accessory): ca. 23 kg (50.7 lbs)
* By default the TeroMatec Wire Feeder 600 will be delivered with wire feeding wheels for 2,8 mm wires.

The power source should be selected according to the welding wire diameter:
wire 1,6 mm
max. 140 A
wire 2,0 mm
max. 210 A
wire 2,4 mm
max. 300 A
wire 2,8 mm
max. 410 A
wire 3,2 mm
max. 530 A

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4.2 Environmental Conditions

Operation or storage of the unit outside the area specified is not considered as
defined use. The manufacturer will not be liable for damage arising as a result of
this.

Temperature range of ambient air:

during operation: +10 C to + 50 C (50 F to 122 F)
during transport and storage: - 20 C to + 55 C (- 4 F to 140 F)

Relative humidity:
0 to 95 % , not condense

Ambient air: free from dust, acids, corrosive gases or substances, etc.

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5.0 DESIGN AND FUNCTIONS

5.1 Construction

5.1.1 TeroMatec WF 600 - Front

Fig. 5.1.1.a: TeroMatec WF 600 - Front

No. FUNCTION
1 Wire-spool / wire-ring holder Wire-spool / wire-ring holder with brake
mechanism to mount standard spools (15 kg) or rings (25 kg).
2 Central torch connector For connecting up the welding torch (welding
current, start contact, wire feed through).
3 Potentiometer for wire feed speed control* Adjusts wire speed rate.
Can be adjusted to increase or decrease electrode feed speed during
welding.
4 Selector switch step mode Selector switch for torch step mode
2-
step / 4-step
5 Option: cooling liquid forward flow Quick coupling for cooling liquid to
the welding torch (blue)
Only at option cooling connection!
6 Option: cooling liquid runback Quick coupling for cooling liquid from
the welding torch (red)
Only at option cooling connection!
* The potentiometer does not give absolute and repetitive speed adjustment. It acts rather to
correct the speed of feeding within a few percentage.

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5.1.2 TeroMatec WF 600 Rear side

10 11

9
12
8
13
7

Fig 5.1.2.a: TeroMatec WF 600 Rear side

No. FUNCTION
7 Option: 1/4 gas port
Gas port for shielding gas (right hand thread)
Only at option gas control!
8 voltage measuring cable Cable to measure the arc voltage; connect to
the work piece;
9 Fuse (10A T) Glas tube fuse for voltage measuring cable;
10 Current socket with bayonet latch
Connection for current cable from power source;
11 Welding wire inlet
12 Option: Plug nipple cooling liquid runback (red) Connect with an
interconnecting hose package to a cooling unit.
Only at option cooling connection!
13 Option: Plug nipple cooling liquid forward flow (blue) Connect with
an interconnecting hose package to a cooling unit.
Only at option cooling connection!

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5.1.3 TeroMatec WF 600 Side view

15

14

16

Fig 5.1.3.a: TeroMatec WF 600 Side view

No. FUNCTION
14 Wire straightener to straighten the welding wire
15 Button wire inching Wire inching (press button downwards): for
currentless wire inching into the torch hose package;
16 4-roller drive Drive with feeder rollers and setscrew for wire contact
pressure.
(The contact pressure must be adjusted, that there is no squeeze and no
slippage on the wire.)

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5.2 Symbols description

SYMBOL DESCRIPTION
Cored wire torch (central torch connector)

2 - stroke

4 - stroke

Work piece connection (voltage measuring line)

Wire inching

** shielding gas connection

* cooling liquid inlet

* cooling liquid outlet

* Only at option cooling connection!

** Only at option gas control!

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5.3 Cooling (Option)

To protect a liquid cooled welding torch from overheating, the torch must be cooled
with cooling liquid.
Liquid cooled welding torches are only allowed to connect to the TeroMatec WF 600
when the unit is equipped with the option cooling connection!

Note!
Check that the cooling circuit is not squeezed or looped to get
the best flow rate of the cooling system and the ideal cooling of
the welding torch.

Attention!
Always check cooling liquid level and quality of the cooling liquid
before unit is started up.

Use only Castolin coolant that is suitable for use in our units due to its special
properties (electrical conductivity, anti-freeze property, material compatibility,
flammability, etc.).
Use only appropriate coolant, do not mix the Castolin Eutectic coolant with other
coolants, do not dilute.
Manufacturer is neither responsible nor liable for damages deriving from use of
other coolants or improper use of Castolin Eutectic dedicated cooling liquid. In this
case also the warranty must be considered void and null.
Transport the coolant in sealed original containers only.
Dispose of used coolant professionally and correctly in accordance with national and
international regulations.
Always check the coolant level in the cooling liquid tank prior to starting any welding.

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6.0 BEFORE START UP / INSTALLATION

6.1 General details

Warning!
Operating the machine incorrectly can cause serious injury and
damage!
Before starting to use the power source, read the section headed
safety rules.

Check before start-up if the specified use and installation of the machine comply
with the section intended use and place of operation.

6.2 Electrical installation

The electrical control system is wired ready for operation.

If the cables and plugs are not ready-mounted, they must be installed according to
national standards. For details of fuse protection of the mains supply lead, please
see the Technical Data.

Attention!
Inadequately dimensioned electrical installations can lead to
serious damage to (or loss of) property.

6.3 Connection scheme

Power source

TeroMatec Wire Feeder 600

- +

Torch
Welding potential/
welding cable

Voltage measuring line

Ground cable

Workpiece
Fig.6.3.a: Connection Scheme

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6.4 Connecting the TeroMatec WF 600 to the power source and the
workpiece

Power source

- +
(a)

(c)

Workpiece (d)
(b)
(e)

Fig.6.4.a: Connecting the TeroMatec WF 600 to

the power source and the workpiece

1. Switch off the main switch of the power source (position 0)

2. Plug the welding potential (a) socket from the power source to the plug and turn
it to latch it.
3. Connect the voltage measuring cable (b) to the workpiece.
4. * Connect the cooling liquid hoses (c) and (d) from a cooling unit colour equal to
the TeroMatec WF 600.
5. ** Plug the gas hose (e) from the pressure reducer to the TeroMatec WF 600.

* Only at option cooling connection!

** Only at option gas control!

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6.5 Connecting the welding torch to the TeroMatec WF 600

(f)

(h) red

(g) blue

Fig.6.5.a: Connecting the welding torch to the TeroMatec WF 600

1. Switch off the main switch of the power source (position 0).
2. Check that the torch is correctly tooled up. Insert it infeed tube first into the
central torch connector (f) and tighten the swivel nut by hand to fix the torch in
place.
3. * Connect up the welding torch hoses for water forward and return flow, as per
the colour markings, to plug the connectors (h) and (i) on the wire feeder.

Note!
It is only possible to use water-cooled welding torches with an
external water connection.
* Only at option cooling connection!

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6.6 Mounting the wire-spool

(i)

Fig.6.6.a: Mounting the wire-spool

Caution!
Risk of injury from the spring effect of the coiled welding wire.
When threading in the wire, hold the end of the wire firmly, to
prevent any injuries that might be caused by the wire flicking
back and recoiling uncontrollably!

1. Switch off the main switch of the power source (position 0)

2. Unscrew the mounting screw (i)
3. Mount the wire-spool onto the wire-spool holder, the right way round, using a
basket-type spool adapter if necessary
4. Latch the locking bolt into the opening provided on the body of the spool or on
the basket-type spool adapter
5. Screw in the mounting screw (i) and adjust the braking force with the screw

Caution!
If the wire-spool were to fall off, this would be dangerous.
Make sure that the wire-spool is firmly mounted to the wire-spool
holder.

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6.7 Feeding in the wire electrode

(l)

(m)
(n)
(k) (o)
(j)
(p)

Fig.6.7.a: Feeding in the wire electrode

1. Switch off the main switch of the power source (position 0)

2. Open the left side panel of the TeroMatec WF 600
3. Pivot clamping device (n) forward
4. Push pressure levers (k) and (o) upward
5. Insert the wire electrode through the infeed tube and the straightener (j) to the 4-
roller drive and around 5 cm into the infeed tube of the welding torch (p)
6. Push pressure levers (k) and (o) downwards
7. Pivot clamping device (n) upward
8. Set the contact pressure by means of clamping screw (m)
9. Arrange the hosepack in as straight a line as possible
10. Detach the gas nozzle from the torch and unscrew the contact tube
11. Plug the mains plug of the power source and shift the mains switch into the I
position
12. Press the wire-inching button (l) until the wire electrode protrudes out of the end
of the torch
13. Screw in the contact tube and fit the gas nozzle
14. Close the left side panel of the TeroMatec WF 600
15. Switch off the main switch of the power source (position 0)

Caution!
Risk of injury from welding wire emerging from the torch.
Hold the welding torch so that it points away from your face and
body.

Note!
The contact pressure must be adjusted, that there is no squeeze
and no slippage on the wire.

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6.8 Changing the feed rollers

In order to achieve satisfactory wire travel, the feed rollers must be suitable for the
diameter and alloy of the wire to be welded.

Important!
Use only feed rollers appropriate to the welding wire!

(m)

(n)
(k) (o)

(t) (u)
(s) (v)
(r) (w)

(q) (x)

Fig.6.8.a: Changing the feed rollers

1. Switch off the main switch of the power source (position 0)
2. Open the left side panel of the TeroMatec WF 600
3. Pivot clamping device (n) forward
4. Push pressure levers (k) and (o) upward
5. Unscrew the screws (q) and (x)
6. Remove the old feeder rollers (r) and (w)
7. Fit the new feeder rollers (r) and (w)
8. Screw in the screws (q) and (x)
9. Unscrew the screws (t) and (u) with a wrench AF13
10. Remove the old feeder rollers (s) and (v)
11. Fit the new feeder rollers (s) and (v)
gear wheel backwards!
12. Screw in the screws (t) and (u) with a wrench AF13
13. Push pressure levers (k) and (o) downwards
14. Pivot clamping device (n) upward
15. Set the contact pressure by means of clamping screw (m)
16. Close the left side panel of the TeroMatec WF 600

Note!
The lower feed rollers have two different sized grooves to use
them for different wire diameters.
Insert the feed rollers in such a way that you can still see and
read the designation for the wire diameter.

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7.0 START-UP

Attention!
The TeroMatec WF 600 must only be operated by appropriately
trained and qualified personnel!

Warning!
Operating the machine incorrectly can cause serious injury and
damage!
Before starting to use the machine, read the section safety
rules!
Only carry out these preparations if
- the mains switch of the power source is in the 0 position,
- the mains cable is unplugged from the mains,
to avoid serious injury and damage!

7.1 Start up
1. Switch off the main switch of the power source (position 0)
2. Unplug the power source from the mains
3. Plug the grounding (earthing) cable into the socket of the power source and
latch it in firmly. With the other end of the grounding (earthing) cable, establish a
connection to the workpiece.
4. Place the TeroMatec WF 600 firmly
5. Connecting the TeroMatec WF 600 to the power source and the workpiece (see
section 6.4)
6. Connecting the welding torch to the TeroMatec WF 600 (see section 6.5)
7. Plug the power supply plug into the mains
8. Switch on the main switch of the power source (1 position)
9. Mount the wire-spool and feed in the wire electrode (see section 6.6 / 6.7)
10. Choose welding torch step mode (see section 7.2)
11. Adjust welding capacity / welding parameters on the power source
12. * Open the gas bottle valve and adjust the required gas quantity
13. Start welding (push torch button)
14. **Adjust wire speed feed rate on the potentiometer of the TeroMatec WF 600.

* Only at option gas control!

** The potentiometer does not give absolute and repetitive speed adjustment. It acts
rather to correct the speed of feeding within a few percentage.

Warning!
An electric shock can be fatal. As soon as the main switch is
switched on (1 position) make sure that from this moment on,
the wire electrode does not touch any persons or electrically
conducting or grounded (earthed) parts such as the housing, etc.

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7.2 Welding torch operating mode (step mode)

7.2.1 Explanation step - mode

SYMBOL DESCRIPTION
t Time

I Welding current

7.2.2 2-step
2-step operation is suitable for:
- Tacking-jobs
- Short weld -seams

Press and hold the torch trigger

Release the torch trigger

t
I

Fig.7.2.2.a: 2-step mode

7.2.3 4- step
4-step operation is suitable for:
- Longer welding seams

Press and hold the torch trigger

Release the torch trigger

t
I
Fig.7.2.3.a: 4-step mode

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7.3 Welding procedure

7.3.1 Arc voltage effects

Arc voltage variations affect the welding operation in the following ways:
High voltage: (long arc length)
High voltage increases spatter and porosity and spreads (flattens) the weld bead
producing an irregular contour.
Low voltage:
Low voltage produces a convex weld bead contour and excessive ripple.
Very low voltage will cause the Wire Feeder to drive the electrode into the work
where it may stick, extinguishing the arc.

7.3.2 Arc current effects

Arc current variations produce the following effects (provided that all other factors
are held constant):
High current:
High current produces flat weld beads and increase melting rate, deposition rate and
penetration of the base material.
Increasing the current permits the use of higher voltages without causing weld bead
porosity and increase wire feed speed.
Low current:
Low current produces a narrow, high contour bead with low penetration. This is an
advantage on thin metals.

7.3.3 Torch travel speed effects

Travel speed variations cause:
High travel speed:
When travel speed is too high, there is shallow penetration and weld beads with
uneven edges. There is a tendency toward increased spatter.
Low travel speed:
When travel speed is too slow, penetration is excessive, slag inclusions become a
problem and the weld bead pattern will become rough and irregular.

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8.0 TROUBLESHOOTING
8.1 General notes
Malfunctions cannot be excluded in spite of the most comprehensive checks and
tests

8.2 Possible malfunctions, causes and corrective action

POSSIBLE
MALFUNCTION
 Motor is not running;
 No wire feeding /
Discontinuous wire feeding
 Wire sticks;
POSSIBLE CAUSE
Welding potential / current
cable or plug from the power
source defective;
Voltage measuring line to the
work piece defective or bad
contact to the work piece;
Ground cable / plug from the
power source to the work piece
defective or bad contact to the
work piece;
Wrong mode selected on the
power source;
Fuse defective;
Motor defective;
No wire;
pivot clamping devices or
clamping screws for set the
pressure are open;
Wrong feeder rollers;
wrong pressure at the clamping
screws;
wrong wire nozzle (at the
torch);
hose from the feeder to the
torch is looped and/or badly
laid;
hose to the torch is too long;
Wire is ensnarl in the wire liner;
CORRECTIVE ACTION
Check cables and plugs and
replace if necessary;
Choose correct mode;
Check fuse and replace if
necessary;
Replace motor;
Insert wire-spool;
Close pivot clamping devices or
clamping screws;
Check feeder rollers and change
if necessary;
Check pressure at the clamping
screws and change if necessary;
Check wire nozzle and change if
necessary;
Place the hose as vertical to the
torch as possible, with no elbows;
Hose to the torch as short as
possible;
Remove wire from the wire liner;
Replace wire liner;

Attention!
Where fuses need to be changed, they must be replaced by fuses
of the same rating. No warranty claims will be accepted in respect
of damage caused by the use of too high a rating of fuse!

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9.0 APPENDIX

9.1 Interface -1X1 (torch)

9.1.1 Configuration
The interface for the torch central plug make available the following signals:

Welding current
Start contact

9.1.2 Plug allocation -1X1

-1X1 torch
PIN FUNCTION
0 Welding current
1 +24 VDC
2 Dig. input (start)

9.1.3 Plug -1X1

Pin configuration

0
1
2

View from outside

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9.2 Main dimensions TeroMatec Wire Feeder 600

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9.3 Options / Accessories

For a complete overview ask your Castolin Eutectic representative.
Options:
TeroMatec 600 gas control
ESC-Code: 754438
Cooling connection
ESC-Code: 754437

Accessories:
Roll set 1,6mm (U-Nut)
ESC-Code: 754431
Roll set 2,0mm (U-Nut)
ESC-Code: 754432
Roll set 2,4mm (U-Nut)
ESC-Code: 754433
Roll set 2,8mm (U-Nut)
ESC-Code: 754434
Roll set 3,2mm (U-Nut)
ESC-Code: 754435
Wire reelers for 25kg
ESC-Code: 754436
Earth cable 6m 95, incl. clamp and plug
ESC-Code: 754365
Earth connection cable 6m 95, incl. plug and bush
ESC-Code: 754366

Recommended torch:
Torch MSG 400 FD with gun moulded recess, 3m (air cooled)
ESC-Code: 302476
Torch MSG 400 FD with gun moulded recess, 3m (liquid cooled)
ESC-Code: 302474
Torch MSG 400 FD, 3m (air cooled)
ESC-Code: 754989
Torch MSG 400 FD, 3m (liquid cooled)
ESC-Code: 712554

Recommended power source:

CastoMatec Xuper 655
ESC-Code: 303170

Operating Manual Page 47 TeroMatec Wire Feeder 600
 Issued June 10

T
Teer
rooM
Maatte
ecc WWF
F660
000 From Serial No
WSN 1004005

10.0 PRODUCT MONITORING

Dear customer,
We are always pleased to help you with our experience. Even in difficult cases we
will be able to advise you. However we are also grateful for information about new
aspects that come to your notice. This is the only way for us to improve our products
where appropriate, in order to make them as safe and reliable as possible.
Also we have a legal obligation to monitor our products beyond the date of delivery.
To provide us with pointers for any rectifications and/or alterations that might be
necessary we are in particular interested in
recurring malfunctions
use other than intended use
improper and/or unsafe operation
bypassing and/or deactivating safety devices
accidents that have occurred
other unusual observations
We kindly ask you to inform us if you become aware of such events.

DATE EVENT REMARK



WE ARE LOOKING FORWARD TO A LONG LASTING COOPERATION AND THANK

YOU FOR THE TRUST PLACED IN US.

Operating Manual Page 48 TeroMatec Wire Feeder 600
 Issued June 10

T
Teer
rooM
Maatte
ecc WWF
F660
000 From Serial No
WSN 1004005

YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

Germany Austria Switzerland Other Countries
Castolin GmbH Castolin Ges.m.b.H. Castolin Eutectic International S.A. Castolin Eutectic International S.A.
Gutenbergstr. 10 Brunner Strae 69 Ch. de la Venoge 7 Export Market Center
D - 65830 Kriftel AT - 1235 Wien CH - 1025 St. Sulpice Case postale 360
Tel. +49 (0) 6192 40 30 Tel. +43 (0) 1 869 45 41 0 Tel. +41 (0) 21 694 11 04 CH 1001 Lausanne
Fax +49 (0) 6192 40 33 14 Fax +43 (0) 1 869 45 41 10 Fax +41 (0) 21 691 55 71 Tel. +41 (0) 21 694 11 11
castolin@castolin.de castolin@castolin.at swiss@castolin.ch Fax +41 (0) 21 694 11 70
export@castolin.ch

www.castolin.com www.eutectic.com

Operating Manual Page 49 TeroMatec Wire Feeder 600