Castolin Eutectic GSI 850 User manual

TÉCNICO
Manual
GSI 850

TABLE OF CONTENTS
0463 730 001 © Eutectic AB 2020
1SAFETY .......................................................................................................
4
1.1 Meaning of symbols...............................................................................
4
1.2 Safety precautions .................................................................................
4
1.3 User responsibility .................................................................................
8
1.4 California Proposition 65 warning ........................................................
10
2INTRODUCTION..........................................................................................
12
2.1 Overview .................................................................................................
12
2.2 Equipment...............................................................................................
12
3TECHNICAL DATA ......................................................................................
13
4INSTALLATION............................................................................................
16
4.1 General ....................................................................................................
16
4.2 Lifting instructions.................................................................................
17
4.3 Location...................................................................................................
18
4.4 Mains supply...........................................................................................
18
5OPERATION ................................................................................................
21
5.1 Overview .................................................................................................
21
5.2 Connections and control devices .........................................................
21
5.3 Connection of welding and return cables ............................................
21
5.4 Turning the mains power on/off ............................................................
22
5.5 Fan control..............................................................................................
22
5.6 Symbols and functions..........................................................................
22
6MAINTENANCE...........................................................................................
25
6.1 Overview .................................................................................................
25
6.2 Power source..........................................................................................
25
6.3 Welding torch..........................................................................................
26
7TROUBLESHOOTING.................................................................................
27
8ORDERING SPARE PARTS ........................................................................
28
DIAGRAM ............................................................................................................
29
ORDERING NUMBERS.......................................................................................
30
ACCESSORIES ...................................................................................................
31
Rights reserved to alter specifications without notice.

1 SAFETY
0463 730 001 - 4 - © Eutectic AB 2020
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
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).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section. Before
performing any installation or operating procedures, be sure to read and follow the
safety precautions listed below as well as all other manuals, material safety data
sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
ear protection. The arc, like the sun, emits ultraviolet (UV) and other
radiation and can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential
to prevent accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets face shields and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
4. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuff less trousers,
high-topped shoes and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.

1 SAFETY
0463 730 001 - 5 - © Eutectic AB 2020
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of
clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also
cause fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Remove all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4. Do not weld, cut or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not do hot work on closed containers, they may
explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. After completing operations, inspect the work area to make certain there are no hot
sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the ground system of the
input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a ground cable.

1 SAFETY
0463 730 001 - 6 - © Eutectic AB 2020
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may
interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when
possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on
the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being
welded.
e) Keep welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therfore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe fumes from these materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other
irritant gases.
4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that ventilation is not adequate. Stop work and take necessary steps to
improve ventilation in the work area. Do not continue to operate if physical discomfort
persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases
which contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's operating instructions for
mounting regulator to a compressed gas cylinder.

1 SAFETY
0463 730 001 - 7 - © Eutectic AB 2020
3. Always secure cylinders in an upright position by chain or strap to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1. Keep all doors, panels, guards and covers closed and securely in place.
2. Stop engine or drive systems before installing or connecting unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
• Keep cables and cords away from moving vehicles when working from an
aerial location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and
maintenance work. Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect
the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power supply in
safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from
heat sources such as furnaces, wet conditions such as water puddles, oil or
grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.

1 SAFETY
0463 730 001 - 8 - © Eutectic AB 2020
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices for
Arc Welding, Cutting and Gouging”, Form 52-529.
The following publications are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
2. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
3. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
4. AWS SP - “Safe practices” - Reprint, Welding Handbook
5. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
Containers That Have Held Hazardous Substances”
6. OSHA 29 CFR 1910 - "Safety and health standards"
7. CSA W117.2 - "Code for safety in welding and cutting"
8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other
Hot Work"
9. CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
Cylinders”
1
0.
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
1.3 User responsibility
Users of Eutectic 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 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
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 equipment must be familiar with:
○its operation
○location of emergency stops
○its function
○relevant safety precautions
○welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○no unauthorised person is stationed within the working area of the equipment
when it is started up
○no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○be suitable for the purpose
○be free from drafts

1 SAFETY
0463 730 001 - 9 - © Eutectic AB 2020
4. Personal safety equipment:
○Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○Make sure the return cable is connected securely
○Work on high voltage equipment may only be carried out by a qualified
electrician
○Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○Lubrication and maintenance must not be carried out on the equipment during
operation
If equipped with Eutectic cooler
Use Eutectic approved coolant only. Non-approved coolant might damage the equipment and
jeopardize product safety. In case of such damage, all warranty undertakings from Eutectic
cease to apply.
Recommended Eutectic coolant ordering number: 0465 720 002.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• 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:
○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.
○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.

1 SAFETY
0463 730 001 - 10 - © Eutectic AB 2020
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and 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 connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• 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.
• To 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
Eutectic has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local Eutectic dealer or visit us on
our website.
1.4 California Proposition 65 warning
WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals
known in the State of Carlifornia to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Section 25249.5 et seq.)

1 SAFETY
0463 730 001 - 11 - © Eutectic AB 2020
WARNING!
This product can expose you to chemicals including lead, which are known to the
state of California to cause cancer and birth defects or other reproductive harm.
Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.

2 INTRODUCTION
0463 730 001 - 12 - © Eutectic AB 2020
2 INTRODUCTION
2.1 Overview
The GSI 850 is a welding power source intended for GMAW welding, as well
as for welding with powder filled cored wire (FCAW-S), for GTAW welding, for welding with
coated electrodes (SMAW) and arc air gouging.
The power sources are intended for use with the following wire feed units:
• SmartFeed 400
• ArcWeld 484
• ArcWeld 420 ST
• ArcWeld 404HD
Eutectic accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power source is supplied with:
• 5 m return cable with earth clamp
• instruction manual

3 TECHNICAL DATA
0463 730 001 - 13 - © Eutectic AB 2020
3 TECHNICAL DATA
For 460 V variants:
GSI 850
Working voltage 380-460 V, ±10%, 3~50/60 Hz
Primary current 380 V 400 V 460 V
Imax. GMAW - MIG 70 A 66 A 58 A
Imax. GTAW - TIG 55 A 52 A 45 A
Imax. SMAW - MMA 70 A 66 A 58 A
Imax. Gouging 70 A 66 A 58 A
No load power in energy-saving mode
6.5 min. after welding 31 W
Setting range for all modes
GMAW - MIG flat characteristic
GTAW - TIG drooping charcteristic
SMAW - MMA drooping characteristic
Gouging
16A/15V – 820 A/44V
10A/10V – 820A/34V
16A/15V – 820A/44V
100A/18V – 820A/44V
Permissible load at GMAW
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Permissible load at GTAW
60% duty cycle
100% duty cycle
820A / 34V
750A / 34V
Permissible load at SMAW
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Gouging
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Power factor at maximum current
GMAW
0.91
GTAW
SMAW
Gouging
Efficiency at maximum current
GMAW
91%
GTAW
SMAW
Gouging
Open-circuit voltage without VRD function 72V DC

3 TECHNICAL DATA
0463 730 001 - 14 - © Eutectic AB 2020
GSI 850
Operating temperature -10 – 40 C° (14 – 104 F°)
Transport temperature -20 – 55 C° (-4 –131 F°)
Constant sound pressure when idling <70 dB (A)
Dimensions l × w × h 32.7 x 16.2 x 24.8 in.
(832 x 413 x 630 mm)
Weight (welding power source) 227 lb (103 kg)
Insulation class H
Enclosure class IP 23
Application class
For 575 V variants:
GSI 850
Working voltage 380-460 V, ±10%, 3~50/60 Hz
Primary current 380 V 400 V 460 V 575 V
Imax. GMAW - MIG 70 A 66 A 58 A 46 A
Imax. GTAW - TIG 55 A 52 A 45 A 36 A
Imax. SMAW - MMA 70 A 66 A 58 A 46 A
Imax. Gouging 70 A 66 A 58 A 46 A
No load power in energy-saving mode
6.5 min. after welding 31 W
Setting range for all modes
GMAW - MIG flat characteristic
GTAW - TIG drooping charcteristic
SMAW - MMA drooping characteristic
Gouging
16A/15V – 820 A/44V
10A/10V – 820A/34V
16A/15V – 820A/44V
100A/18V – 820A/44V
Permissible load at GMAW
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Permissible load at GTAW
60% duty cycle
100% duty cycle
820A / 34V
750A / 34V
Permissible load at SMAW
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Gouging
60% duty cycle
100% duty cycle
820A / 44V
750A / 44V
Power factor at maximum current

3 TECHNICAL DATA
0463 730 001 - 15 - © Eutectic AB 2020
GSI 850
GMAW
0.91
GTAW
SMAW
Gouging
Efficiency at maximum current
GMAW
91%
GTAW
SMAW
Gouging
Open-circuit voltage without VRD
function 72V DC
Operating temperature -10 – 40 C° (14 – 104 F°)
Transport temperature -20 – 55 C° (-4 – 131 F°)
Constant sound pressure when idling <70 dB (A)
Dimensions l × w × h 32.7 x 16.2 x 24.8 in.
(832 x 413 x 630 mm)
Weight (welding power source) 227 lb (103 kg)
Insulation class H
Enclosure class IP 23
Application class
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0463 730 001 - 16 - © Eutectic AB 2020
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.

4 INSTALLATION
0463 730 001 - 17 - © Eutectic AB 2020
4.2 Lifting instructions

4 INSTALLATION
0463 730 001 - 18 - © Eutectic AB 2020
WARNING!
Secure the equipment - particularly
if the ground is uneven or sloping.
4.3 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
4.4 Mains supply
NOTE!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply,
influence the power quality of the grid. Therefore connection restrictions or
requirements regarding the maximum permissible mains impedance or the required
minimum supply capacity at the interface point to the public grid may apply for some
types of equipment (see technical data). In this case it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the distribution
network operator if necessary, that the equipment may be connected.
Make sure that the welding power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made in
accordance with regulations.
1. Rating plate with supply connection data
GSI 850
Mains voltage 380V 3~ 50/60 Hz 400V 3~ 50/60 Hz
Mains cable area 4x16 mm24x16 mm2
Recommended fuse sizes and minimum cable area GSI 850

4 INSTALLATION
0463 730 001 - 19 - © Eutectic AB 2020
GSI 850
Phase current Ieff 65 A 62 A
Fuse
anti-surge
type C MCB
70 A 66 A
GSI 850
Mains voltage 415V 3~ 50/60 Hz 440V 3~ 50/60 Hz
Mains cable area 4x16 mm24x12 mm2
Phase current Ieff 60 A 56 A
Fuse
anti-surge
type C MCB
64 A 60 A
GSI 850
Mains voltage 460V 3~ 50/60 Hz 575V 3~ 50/60 Hz
Mains cable area 4x12 mm24x8 mm2
Phase current Ieff 54 A 43 A
Fuse
anti-surge
type C MCB
58 A 46 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant national
regulations.
Supply from power generators
The power source can be supplied from different types of generators. However, some
generators may not provide sufficient power for the welding power source to operate
correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better
type of regulation, with rated power ≥75 kW, are recommended.

4 INSTALLATION
0463 730 001 - 20 - © Eutectic AB 2020
Connection instruction
The power source GSI 850 CC/CV (0445 555 881) for North America is
connected to 460 V from the factory.
If a different mains voltage is required, the cover plate has to be removed and switch can be
positioned for the required voltage.
Installation of mains cable
A mains cable needs to be installed. It is then important that the earth connection to the
bottom plate must be made in a correct way. See the picture above for the order in which
the washers, nuts and screws are placed.