Castolin Eutectic ArcWeld 420i User manual

ArcWeld 420i
Instruction manual

TABLE OF CONTENTS
0446 924 001 GB - 2 - © Eutectic AB2020
1 SAFETY ......................................................................................................................... 3
1.1 Meaning of symbols ............................................................................................... 3
1.2 Safety precautions ................................................................................................. 3
2 INTRODUCTION............................................................................................................ 6
2.1 Overview ..................................................................... Erro! Indicador não definido.
2.2 Equipment ............................................................................................................... 6
3 TECHNICALDATA ........................................................................................................ 7
4 INSTALLATION ............................................................................................................. 8
4.1 Overview ................................................................................................................. 8
4.2 Lifting Instructions ................................................................................................ 8
5 OPERATION .................................................................................................................. 9
5.1 Overview ................................................................................................................. 9
5.2 Connections and control devices ...................................................................... 10
5.3 Wire feed pressure............................................................................................... 11
5.4 Wire inching.......................................................................................................... 11
5.5 Replacing and inserting wire .............................................................................. 12
5.6 Changing rollers................................................................................................... 12
6 MAINTENANCE........................................................................................................... 13
6.1 Overview ................................................................................................................ 13
6.2 Inspection and cleaning ...................................................................................... 13
7 WIRING DIAGRAM...................................................................................................... 14
8 ORDERING SPARE PARTS ....................................................................................... 15
WEAR PARTS ..................................................................................................................... 16
ORDERING NUMBERS....................................................................................................... 17
ACCESSORIES ................................................................................................................... 18
Rights reserved to alter specifications without notice

1SAFETY
0446 924 001 GB - 3 - © Eutectic AB2020
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
1.2 Safety precautions
Users of EUTECTIC welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions.
Safety precautions must meet the requirements that apply to this type of welding equipment.
The following recommendations should be observed in addition to the standard regulations
that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
welding equipment. Incorrect operation of the equipment may lead to hazardous situations
which can result in injury to the operator and damage to the equipment.
1 Anyone who uses the welding equipment must be familiar with:
o its operation
o location of emergency stops
o its function
o relevant safety precautions
o welding
2 The operator must ensure that:
o no unauthorized person is stationed within the working area of the equipment
when it is started up.
o no-one is unprotected when the arc is struck or work is started with the
equipment
3 The workplace must:
o be suitable for the purpose
o be free from drafts
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer’s safety practices and
Safety Data Sheets (SDSs).

1SAFETY
0446 924 001 GB -4 - © Eutectic AB2020
4 Personal safety equipment:
o Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves.
o Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5 General precautions:
o Make sure the return cable is connected securely.
o Work on high voltage equipment may only be carried out by qualified
electricians.
o Appropriate fire extinguishing equipment must be clearly marked and close at
hand.
o Lubrication and maintenance must not be carried out on the equipment during
operation.
ELECTRIC SHOCK -Can kill
 Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
 Insulate yourself from work and ground.
 Ensure your working position is safe.
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
 Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
 Exposure to EMF may have other health effects which are unknown.
 Welders should use the following procedures to minimize exposure to EMF:
o Route the electrode and work cables together on the same side of your
body. Secure them with tape when possible. Do not place your body
between the torch and work cables. Never coil the torch or work cable
around your body. Keep welding power source and cables as far away
from your body as possible
o Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
 Keep your head out of the fumes
 Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area
WARNING!
Wire feeders are intended to be used with power sources in MIG/MAG mode only.
If used in any other welding mode, such as MMA, the welding cable between wire
feeder and power source must be disconnected, or else the wire feeder becomes
live or energized
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting

2INTRODUCTION
0446 924 001 GB -5 - © Eutectic AB2020
ARC RAYS - Can injure eyes and burn skin
 Protect your eyes and body. Use the correct welding screen, filter lens and
wear protective clothing
 Protect bystanders with suitable screens or curtains
NOISE- Excessive noise can damage hearing
 Protect your ears. Use earmuffs or other hearing protection
MOVING PARTS - Can cause injuries
 Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
 Stop engine before installing or connection unit.
 Keep hands, hair, loose clothing and tools away from moving parts
FIRE HAZRAD
 Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
 Do not use on closed containers
HOT SURFACE - Parts can burn
 Do not touch parts bare handed.
 Allow cooling period before working on equipment.
 T0 handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.

2INTRODUCTION
0446 924 001 GB -6 - © Eutectic AB2020
2 INTRODUCTION
2.1 Overview
The ArcWeld 420iis a wire feed unit intended for MIG/MAG & FCAW welding together with
the welding power sources.
MIGArc 6200i
MIGArc 4200i
They can be used with wire bobbins up to Ø300mm.The wire feed unit can be placed on
the machine or on the floor during the operation
EUTECTIC’s accessories for the product can be found on page 18.
2.2 Equipment
The ArcWeld 420iwire feed unit is supplied with
● Instruction manual
● Two Ø1.0/1.2mm V-groove (assembled)
● Two Ø1.2/1.6mm Knurled V-groove (in package)

3TECHNICAL DATA
0446 924 001 GB -7 - © Eutectic AB2020
3 TECHNICALDATA
ArcWeld 420i
Power supply
24VDC
Power requirement 120 VA
Input supply current Imax 3 A
Setting range
Wire feed speed 1.5 - 25.0 m/min
Torch connection EURO
Max. diameter wire bobbin 300 mm
Wire dimension 0.8 - 1.6 mm
Weight 15 kg
Dimensions (LxWxH) 635 x 250 x 390 mm
Operating temperature -10 to +40°C
Transport and storage
temperature
-20 to +55°C
Shielding gas All types intended for MIG/MAG welding
Max pressure 8 bar
Permissible load at
60% duty cycle 500 A
100% duty cycle 400 A
Enclosure class IP2X
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at
a certain load without overloading. The duty cycle is valid for temperatures up to 40°C
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP2X is intended for indoor use.

4INSTALLATION
0446 924 001 GB -8 - © Eutectic AB2020
4 INSTALLATION
4.1 Overview
The installation must be executed by a professional
4.2 Lifting Instructions
CAUTION!
Risk of crushing when lifting the wire feeder. Mounting a large wire bobbin, may
change the center of gravity of the wire feeder and increase the risk of tipping and
crushing. Protect yourself and warn bystanders of the risk
CAUTION!
To avoid personal injury and / or damage, lift using method and attachment points
shown here.
NOTE!
This wire feeder is intended for manual handling only.
Do not use mechanical lifting means to lift the wire
feeder with wire spool. DANGER!
WARNING!
When welding in an environment with increased electrical risk, only power sources
intended for this environment may be used. These power sources are marked with
symbol

5OPERATION
0446 924 001 GB -9 - © Eutectic AB2020
5 OPERATION
5.1 Overview
General safety regulations for the handling the equipment can be found in the “SAFETY”
chapter of this manual. Read it through before you start using the equipment!
WARNING!
To avoid shock, do not touch electrode wire or parts in contact with it, or uninsulated
cable or connections.
NOTE!
When moving the equipment, use handle intended for transportation. Never pull the
equipment by the welding torch.
WARNING!
Risk of crushing! Do not use safety gloves when replacing the wire, feed rollers and
wire bobbins.
CAUTION!
Before threading welding wire, make sure the chisel point and burrs have been
removed from the end of the wire to prevent the wire from jamming in the torch liner.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
To prevent the reel from sliding off
the hub, lock the reel by tightening
the nut anti clockwise!

5OPERATION
0446 924 001 GB -10 - © Eutectic AB2020
5.2 Connections and control devices
1 Connection for welding torch
(Euro)
2 Knob for setting wire feed speed
3 Button for wire inching
4 Knob for setting the voltage
5 Brake hub
6 Connection for welding current
from power source
7 Connection for control cable from
power source
8 Connection for shielding gas
9 Reel cover

6MAINTENANCE
0446 924 001 GB -11 - © Eutectic AB2020
5.3 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then set the
pressure of the wire feeder's pressure rollers. It is important that the pressure is not too
great.
To check that the feed pressure is set correctly, you can feed out the wire against an
insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (Fig. 1) the feed rollers
should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be fed out
and bend (Fig. 2)
5.4 Wire inching
Wire inching is used to feed wire without welding voltage and gas flow. The wire is fed as long
as the button is depressed. Wire inching speed can be adjusted by the speed setting knob
CAUTION!
Before pressing the inching button make sure, the speed is set to the required
value.

6MAINTENANCE
0446 924 001 GB -12 - © Eutectic AB2020
5.5 Replacing and inserting wire
● Disconnect the pressure locking device by folding it forward, slide the pressure roller
up.
● If necessary, roll back the wire and remove the wire bobbin.
● Straighten out 10-20 cm of the new wire. File burrs and sharp edges from the end of
the wire before inserting it into the wire straightener & feed unit.
● Make sure that the wire goes properly into the feed roller's track and into the outlet
nozzle & wire straightener’s grooves.
● Secure the pressure locking device & tighten the wire straightener slightly.
5.6 Changing rollers
● Disconnect the pressure locking device (1) by folding down.
● Remove the snap spring (3) with a screwdriver and pull out the shaft to disconnect
the pressure Roller (2).
The pressure roller is disconnected.
● Disconnect the feed roller (4) by unscrewing the nut (5) and pulling out the rollers.
(Take note of the woodruff key that is used to turn the feed roller)
● During installation, repeat the above in reverse order.
Choice of track in the feed roller
Turn the feed roller towards the wire feeder with the dimension mark of the required track.

6MAINTENANCE
0446 924 001 GB -13 - © Eutectic AB2020
6 MAINTENANCE
6.1 Overview
6.2 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
● Cleaning and replacement of the wire feed unit mechanism's worn parts should
take place at regular intervals in order to achieve trouble-free wire feed. Note that
if pre-tensioning is set too hard, this can result in abnormal wear on the pressure
roller, feed roller and wire guide.
The brake hub
The hub is adjusted when delivered, if readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly slack when wire feed stops.
● Adjusting the braking torque:
- Remove the spool locking lever by turning it counter-clockwise.
- Insert an allen key into the bolt in the hub.
- Turn the springs clockwise to reduce the braking torque
- Turn the springs counter-clockwise to increase the braking torque.
Welding torch
● Cleaning and replacement of the welding gun's wear parts should take place at
regular intervals in order to achieve trouble-free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period

7WIRING DIAGRAM
0446 924 001 GB -14 - © Eutectic AB2020
7 WIRING DIAGRAM
ArcWeld 420i
R1
D2 D1
TS IPB
VRa
VRv
R1
SOL
M
+
1 2 3 4 5 6 7
Circuit part schedule
Marking Name Specifications Quantity
M Wire Feeder Motor 120SN 1
SOL solenoid valve DC24V 1
TS trigger switch Standard fitting of
welding torch
IPB inching switch 250VAC 1
R1 Resistance 10KΩ/1W 1
VRv/VRa Voltage/WFS
control RV28P/4.7K 2
D1. D2 Diode 045D(IN4007) 2

8ORDERING SPARE PARTS
0446 924 001 GB -15 - © Eutectic AB2020
8 ORDERING SPARE PARTS
To find the required spare part, please refer to the Spare Parts List as shown on page 11.
Spare parts may be ordered through your nearest EUTECTIC dealer. See the last page of
this publication to find the nearest EUTECTIC office or dealers, see Eutectic.com. When
ordering, please state product type, serial number, designation and spare part number in
accordance with the spare parts list. This facilitates dispatch and ensures correct delivery
CAUTION!
Repair and electrical work should be performed by an authorized Eutectic service
technician. Use only Eutectic original spare and wear parts

WEAR PARTS
0446 924 001 GB -16- © Eutectic AB2020
WEAR PARTS
Item Qty Ordering no. Denomination Notes
1
2 0700 020 099 Feed Roller, Ø 0.8 - 1.0 mm, V groove For Fe &Ss wires
2 0700 020 085 Feed Roller, Ø 1.0 - 1.2 mm, V groove For Fe &Ss wires
2 0700 020 086 Feed Roller, Ø 1.2 - 1.6 mm, V groove For Fe &Ss wires
2 0700 020 070 Feed Roller, Ø 1.2 - 1.2 mm, Knurled V groove For cored wires
2 0700 020 087 Feed Roller, Ø 1.2 - 1.6 mm, Knurled V groove For cored wires
2 1 0700 020 082 Outlet Guide (Ø4×Ø2×46) SS Tube incl. circlip
3 1 0700 020 083 Outlet Guide (Ø4×Ø1.6×46) SS Tube incl. circlip

ORDERING NUMBERS
0446 924 001 GB -17- © Eutectic AB2020
ORDERING NUMBERS
Ordering no. Description
0700 020 004 ArcWeld 420i
0446 925 001 Spare parts list
The spare parts list is available on the internet at www.eutectic.com.br

ACCESSORIES
0446 924 001 GB -18- © Eutectic AB2020
ACCESSORIES
Item Accessory GIN Number
1 5m 70mm2 interconnection cable 0349 490 624
2 10m 70mm2 interconnection cable 0349 490 608
3 15m 70mm2 interconnection cable 0349 490 607
4 25m 70mm2 interconnection cable 0349 490 606

Eutectic do Brasil
R. Arthur Barbarini, 959 - CEP 13347-436 - Tel.: [phone]
Distrito Industrial - Indaiatuba – SP
• BELO HORIZONTE: Tel.: [phone] - FAX: [phone]
Internet: http://www.eutectic.com.br
24/12/2020 Rev.00