Eutectic Castolin GSX 750 ITAIPU User manual

3
Instruction Manual
Spare parts list
Contents
01 - Description.............................................................. 4
02 - Safety procedures .................................................. 4
03 - Duty cycle ............................................................... 5
04 - Technical characteristics ........................................ 5
05 - Controls and components...................................... 5
06 - Installation............................................................... 6
07 - Operation................................................................ 7
08 - Maintenance ........................................................... 7
09 - Repair...................................................................... 7
10 - Electrical diagram................................................... 8
11 - Spare parts ............................................................. 9

4
1 - Description
1.1 - General
GSX 750 rectifier is a power source with
constant current characteristics projected
for welding with coated electrodes using
direct current.
Ideal for welding of Carbon steels, alloyed
steels, stainless steels, cast Iron, Aluminum
and its alloys, Copper and bronze.
Welding current can be continuously ad-
justed to any application in within utiliza-
tion range by means of a crank installed
on front panel.
Suitable for electrodes up to 6,0mm.
GSX 750 rectifier cabinet offers sound
construction and can be easily moved all
about working place. Cart is provided with
brakeage and lifting devices.
2 - Safety procedures
Following care must always be taken prior
to start any welding operation:
Eye protection
Always wear welding helmet with ap-
propriate glass to protect eyes and face
(Table 1).
Welding current (A) Glass nº
30 - 75 8
75 - 200 10
200 - 400 12
over 400 14
Table 1: Adequate eye protection in
relation to welding current
Body protection
Insulating leather gloves must always be
worn on both hands. For complex jobs re-
quiring high moving and precise electrode
holder positioning, wear fine leather glo-
ves. Delicate welding jobs with low current
intensity allow use of woven fabric gloves.
Entire body must be protected against ul-
tra-violet rays emitted by the electrical arc.
Ventilation
Welding should never be performed in
completely enclosed spaces without ade-
quate means to exhaust gases and fumes.
Electrical protection
When handling with any electrical equipment,
special care must be taken to avoid contact
with “live” parts (that is, which are under ten-
sion) without appropriate protection.
Solid, insulating rubber footwear should
be worn, even thus do not step on wet
ground while welding.
Check electrode holder and cables, they
must offer perfect conditions without worn-
out, burnt or unthreaded parts.
Equipment mus be totally disconnected
from mains prior to open cabinet. Ground
cable, supplied together with feeding ca-
ble, must be permanently connected.
Fire protection
Paper, straw, wood, woven fabrics, cot-
ton tow and any other flammable mate-
rial must be removed from welding area.
Containers for inflammable material must
be thoroughly rinsed and dried, free of any
residual vapours.
Chlorinated solvents such as Carbon
tetrachloride and trichloretylene, al-
though not inflammable, if not thorou-
ghly dried originate gases of high toxi-
city when in contact with electrical arc.
In case of fire or short-circuit, never
throw water on any electrical equip-
ment. Immediatly disconnect equip-
ment from mains and use carbonic gas
or chemical powder fire extinguisher to
eliminate flames.

5
3 - Duty cycle
Duty cycle is the rate between the period
of time a welding equipment can supply
a given maximum welding current (load
time) and a reference time which, as per
international rules, is considered to be 10
minutes.
Nominal duty cycle of 60% means that
equipment can repeatedly supply its nomi-
nal welding current during periods of 6 mi-
nutes (load), each period being followed
by a resting period (when equipment does
not supply welding current) of 4 minutes (6
+ 4 = 10 minutes). Such cycle is repeated
without internal components overheating
(as per equipment project pre-established
limits). Same reasoning applies to any
duty cycle value.
In GSX 750 rectifier, allowed duty cycle
increases up to 100% as welding current
being used decreases; inversely, allowed
duty cycle decreases as welding current
increases up to maximum range.
4 - Technical characteristics
TECHNICAL CHARACTERISTICS
ABNT class II
Current range (A) 70 - 750
Nominal current (A) 600 @ 60%
No-load voltage maximum (V) 76
Permitted loads:
Dutty cycle (%) 400 @ 100 %
Current (A) 230 600 750
Tension (V) 30 32 37
Electrical feeding (V-Hz) 220 / 380 / 440 - 60
Apparent nominal power (KVA) 24,3
Thermal class H (180°C)
Dimensions (w x l x h - mm) 780 x 950 x 870
Weight (kg) 225
Table 2: GSX 750 technical characteristics
5 - Controls and components
5.1 - Front panel

6
1 - On/Off switch = allows operator
to switch on and switch off the
equipment
2 - Negative outlet terminal = for
working cable connection
3 - Positive outlet terminal = for
electrode-holder cable connection
4 - Crank = allows welding current value
adjustment
5 - Pilot lamp = when lit on indicates
that equipment is energized
6 - Auxiliar socket 220V = for auxiliar
equipment feeding
Obs.: Crank scale graduation is a referen-
ce for current range
6 - Installation
6.1 - Reception
When receiving a GSX 750 rectifier, you
should remove all packaging material in-
volving the equipment and check for even-
tual damages which could have occurred
during transportation. Any complaint rela-
ted to damages occurred during transpor-
tation should be directed to the transporter
company.
All material that could obstruct refrigera-
ting air circulation must be removed.
6.2 - Working area
A free space of at least 700mm should be
left all around GSX 750 rectifier in order to
allow its adequate ventilation as well as to
permit proper operation and easy access
in case of preventive or corrective mainte-
nance.
Installation of any air filtering device redu-
ces available refrigeration air volume and
can generate internal components overhe-
ating.
Installation of any filtering device not au-
thorized by supplier, cancels equipment
warrantee.
6.3 - Electrical feeding
Electrical feeding tension requirements
are mentioned on the nominal plate. GSX
750 is projected to operate in triphasis
mains of 220, 380 or 440 V, 60 Hz.
For a GSX 750 rectifier electrical feeding,
the feeding cable supplied together with
the equipment can be used (4 conductors
being 3 for feeding and 1 for grounding).
Or an appropriate cable with diameter cor-
responding to desired length and with 4
conductors, being 3 for feeding and 1 for
grounding. In any case, electrical feeding
must be done through an exclusive wall-
switch with fuses or protective circuit-bre-
akers adequately dimensioned.
Table below indicates cables and fuses
dimensioning:
Feeding
tension
(V)
Consumption
at nominal
load (A)
Feeding
conductors
(Copper - mm2)
Retarding
fuses
(A)
220 64 10 80
380 38 10 50
440 32 10 40
Table 3: Cables and fuses dimensioning
GSX 750 rectifier is supplied to be con-
nected to a 440 V feeding system. In case
feeding tension is different, primary con-
nections should be adapted as indicated
in the electrical diagram. Remotion of left
cabinet lateral allows direct access to the
set of primary connections terminals.
Important!
Grounding terminal is connected to GSX
750 rectifier chassis. It should be connec-
ted to an efficient grounding point of the
general electrical installation. Do not con-
nect grounding conductor of feeding ca-
ble to any on-off switch terminals because
such procedure would generate electrical
tension on equipment chassis.
All electrical connections must be well
fastened in order to eliminate risks of spa-
rkling, overheating or tension dropping in
circuits.

7
Do not use electrical system “neutral”
for grounding connection.
6.4 - Welding circuit
GSX 750 rectifier good performance de-
pends on use of a Copper working cable,
insulated, in optimal conditions, firmly fas-
tened to its terminals, as short in length as
possible and compatible with considered
applications. Also connections to work
piece or to working bench and “negative”
terminal should be well fastened.
No matter its lotal length (which should
always be as short as possible) and no
matter the welding current in use, the dia-
meter of working cable should correspond
to maximum current GSX 750 rectifier can
supply at 60% duty cycle.
Electrical resistance of welding circuit
causes tension dropping allied to internal
dropping (natural of rectifier itself) genera-
ting reduction in arc tension and maximum
current available, making arc unstable.
7 - Operation
After connecting GSX 750 to mains and
properly connecting electrode-holder and
working cable:
1 - Put on-off switch in “on” position.
Exhauster engine starts rotating so
providing necessary refrigeration air
flow to the equipment.
2 - Pre-adjust welding current using
crank on front panel. By rotating
crank clock-wise, current value
increases; by rotating it in the
opposite direction, current value
decreases.
Attention!
Welding parameters adjustment will ba-
sically depend on electrode material and
diameter, on work piece width and welding
position.
3 - Proceed to arc ignition and, if
necessary, adjust current.
8 - Maintenance
Under normal operation conditions, GSX
750 rectifier does not require special main-
tenance. It is enough to clean it internally,
once in a month, using dry and oil free
compressed air at low pressure.
After this procedure, check electrical
connections and components fastening.
Check as well eventual damage signs
on electrical wiring and cables, including
working cable and other insulating mate-
rials. Replace them in case of any damage
signs.
When overloaded due to lack of refrigera-
tion or working conditions not projected
by Eutectic do Brasil, rectifying bridge can
be damaged by opening or short-circuit.
Under these circumstances, no-load volta-
ge is inferior to recommended value and
rectifying bridge should be replaced.
9 - Repair
In order to assure optimum performance of
an Eutectic equipment, only original spare
parts, supplied or approved by Eutectic do
Brasil, should be used. Utilization of non-
original or non-approved parts cancels the
warranty.

8
10 - Electrical diagram

9
11 - Spare parts

10

11

12

13
11.1 - Transformer - front view

• BELO HORIZONTE: Tel.: 0(XX)31-2191-4488 - FAX: 0(XX)31-2191-4491
• RIBEIRÃO PRETO: 0(XX)16-624-6486 - FAX: 0(XX)16-624-6116
• CURITIBA: Tel.: 0(XX)41-339-6207 - FAX: 0(XX)41-339-6234
• PORTO ALEGRE: Tel.: 0(XX)51-3241-6070 - FAX: 0(XX)51-3241-6070
• RECIFE: Tel.: 0(XX)81-3327-2197 - FAX: 0(XX)81-3327-6661
• SALVADOR: Tel.: 0(XX)71-374-6691 - FAX: 0(XX)71-374-6703
EUTECTIC DO BRASIL LTDA.
R. Ferreira Viana, 146 - CEP 04761-010 - Toll Free: 0800 7034370 - Tel.: 0(XX)11-2131-2300 - Fax: 0(XX)11-2131-2393 - São Paulo - SP
Internet: http://www.eutectic.com.br