Plasma Transferred Arc Technology

EuTronic GAP 3001 DC

PlasmaTech
The Plasma Welding Unit for high duty
applications
350 A maximum output for high welding speeds.
Suitable for joining, coating and brazing.
Versatile and flexible due to the modular
construction.
Wide range of accessories to fit every application.
Memory available for storing up to 100 welding
routines for easy repeatability of applications.
Optional automation and software interfaces.
Why EuTronic GAP
The EUTRONIC GAP is the Castolin Eutectic plasma
transferred arc (PTA) process ideal for joining and coat-
ing operations.
Compared to conventional arc welding, plasma offers a
range of outstanding advantages:
High energy density in an extremely focused arc
High deposition rates for shorter welding times
Homogeneous, pore and spatter free coatings
Lowest dilution, heat input, distortions and -
HAZ than any other arc welding process
Maximum purity and performance of the weld-
ing alloy
Extra smooth surface that allows lower post
welding machining costs
Exceptional reproducibility
Suitable for automated processes
The EuTronic GAP family develops
After 100 years of history and more than 30 years experi-
ence in PTA development, Castolin Eutectic introduces the
new generation of PTA power sources.
This family of machines is based on high-power inverters
for stepless generation and control of welding and pilot
arc current.
The EuTronicGAP 3001 features a standard plasma gas
electronic control valve and all the necessary interfaces to
drive external feeding devices.
A new, powerful PLC controls all the functions: the user
friendly menus enable all the parameters to be entered
and all the error messages to be displayed in plain text on
the front LCD.
Its memory allows storing up to 100 user welding routines.
Versatile in use
With the GAP 3001 DC it is possible to combine multiple
processes on a wide range of base materials:
Plasma welding Plasma brazing
Plasma powder welding Cold wire Tig welding
Cold wire plasma welding Tig and MMA welding

Focused plasma arc allows extra control, that results also in
low dilution and smooth surface coatings
Flexible Communication
The EuTronicGAP 3001 DC is a highly sophisticated but
user friendly equipment. It can be used in manual mode
but has been mainly designed for installing on robots and
for integration in fully automated processes.
A 72 pin Harting and a profi bus interface for all com-
mon protocols are available as optionals.
For better control and display of all the process param-
eters, an additional optional software package, the GAP
Control, has been designed.

The GAP Control (optional).....

....is the easy and user friendly software, that allows displaying and
setting of all the welding and inverter parameters.
Reports can be generated for quality control issues and, when installed
in fully automated systems, rejects can be authomatically removed
from the production cycle.
The minimum hardware requirements, processor Intel 486 or higher,
Win98, RS232 interface, allow running it on almost every PC and
Laptop.
Different password protected levels are set to prevent the system and
delicate settings from unauthorised use.
The GAP Control includes additional features such as the possibility to
modify the functions assigned to digital and analog inputs-outputs .
It also extends the memory capacity of the equipment to unlimited as
welding routines can be uploaded from inverter to PC and viceversa.

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 Equipment and Accessories for every application
The EuTronicGAP 3001 DC, due to its modular design, can be adapted to any application just choosing the right accessories.

EuTronicGAP 3001 DC: ESC 260065

Pilot arc current: 3 - 60 A
max 30 A 100% Duty Cycle
Welding current: 6 - 350 A
Max welding arc current: 250 A 100 % Duty Cycle
320 A 60 % Duty Cycle
350 A 50% Duty Cycle
Open-circuit V main-pilot inverter: 80V - 110V
Voltage supply: 3x400V + N 10%
Supply frequency: 50/60 Hz
Supply fuse: 32 A
Degree of protection: IP 23
Plasma gas adjustment: Electronic valve, 0.1-5.0 lt/min, inlet pressure 2.5 bars
Shielding gas adjustment: Manual flowmeter, 2-20 lt/min, inlet pressure 2.5 bars
Transport gas adjustment: Manual flowmeter, 0.5-4.2 lt/min, inlet pressure 2.5 bars
Dimensions (L x W x H): 815 x 445 x 635 mm
Weight: 77 kg

Powder Feeder EP2: ESC 260229

Carrier gas: Ar, Ar-H2
Cold Wire Feeder KD2: ESC 400560
Carrier gas ow rate: 0 - 4 l/min
Wire feed rate: 0 8 m/min
Powder reservoir: 2 l capacity
Wire feed rolls: 0.8 2.8 mm
Degree of protection: IP 23
Degree of protection: IP 23
Weight (without powder): 7.5 kg
Weight: 17.2 kg
Dimensions (L x W x H): 200 x 170 x 470 mm
Dimensions (L x W x H): 705 x 280 x 420 mm
Feeding rate stepless controlled via feeding wheel speed
Speed controlled for continuous or pulsed feeding mode and
directly from inverter PLC. Powder feed rate 3-120 g/min,
wire retraction. Higher wire feed speed option on request
depending on feeding wheel conguration, torch, anode
and powder density.

Cooling GAP (*): ESC 260058

Weight: 40 kg
Dimensions (L x W x H): 900 x 445 x 360mm
Trolley: ESC 260056
Cooling GAP Twin: ESC 260059 Weight: 45 kg
Weight: 45 kg Dimensions (L x W x H): 1.190 x 740 x 1.415 mm
Dimensions (L x W x H): 900 x 445 x 360mm Holds gas bottles, powder feeder, power source and cooler
(*) Use only Castolin Eutectic dedicated cooling liquid

Castolin Eutectic PTA consumables

Castolin Eutectic manufactures and offers a wide and complete range of alloys, available
in different forms, that covers almost every application and any plasma welding process:

Microatomised Ni, Co, Fe or Cu based powders for wear resistant coatings

Laser wires, laser and Tig rods for manual and micro plasma welding
Solid and flux cored wires for cold wire plasma welding

Ask your local Castolin Eutectic representative for more information.

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 PTA Torches (*) GAP E 52 GAP E 42 GAP E 54 S-M-D-DL GAP E 80 GAP E 12 N
Torch type: Powder machine torch Powder machine torch Powder machine torch Powder manual torch Wire manual torch

for universal applications for high duty for inner coatings of parts with
diameters > 80 mm and length
up to 1.7 m.

Available in four different

lengths: 330(S) - 550(M)
920(D) - 1.770(DL) mm

Construction: Vertical Vertical Horizontal Horizontal Horizontal

Max. current intensity

(100% duty cycle): 200 A 200 A 200 A 80 A 100 A

Powder ow rate **: 3 80 g/min 3 140 g/min 10 40 g/min 5 20 g/min ----------

Cooling: Liquid Liquid Liquid Liquid Liquid

Weight with hose pack: 4.8 kg (4 m) 3.7 kg (4 m) 10 kg (10 m) 2 kg (3 m) 1.9 kg (4 m)

Dimensions (L x W x H): 75 x 35 x 60 mm 87 x 45 x 77 mm 330 - 550 - 920 - 1.770 x 55 x 70 mm 240 x 30 x 70 mm 260 x 25 x 65 mm

ESC 3m - - - 400 700 -

for torch with 4 m 400 204 400 238 400 861(S) 400 928(D) - 400 900

hose pack length 10 m 400 212 400 240 400 715(S) 400 270(D) - -
402 260(M) 400 275(DL)

* Additional PTA torches and accessories can be developed on request!

** Max feeding rate depending also on powder density, powder feeder settings and type of anode

Application Oriented Design

Castolin Eurectic develops and manufactures PTA welding
units and accessories in various models and sizes either as
standard units or as special developments.
Our team of technicians will be able to design with you
the cost effective and taylor made solution that fits your
specific application.
From power source to feed unit, welding torch, even han-
dling devices or robots when required, we take care of all
the details.

A complete range of
anodes, powder and
gas nozzles has been
designed and is con-
stantly improved to
allow ideal access,
feeding and fusing of
powder, even on the
most difficult parts.

YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

Switzerland
Castolin Eutectic Intl. S.A.
Case postale 360
CH-1001 Lausanne
Tl. +41.21. 694.11.11
Fax +41.21. 694.11.70
U.S.A.
Eutectic Corporation
N94 W14355 Garwin Mace Drive
Menomenee Falls WI 53051
Tel. +1 (262) 255.55.20
Fax. +1 (262) 255.55.42
Australia Germany
Eutectic Australia Pty. Ltd. Castolin GmbH
Unit 21, 317-321 Woodpark Road Gutenbergstrae 10
Smithfield NSW 2164 Sydney D-65830 Kriftel
Tel. +61.2. 87.86.37.05 Tel. +49.6192. 40.30
Fax +61.2. 97.25.33.76 Fax +49.6192. 40.33.14

We reserve the right to improve or modify these information or technical specifications without previous notice. by Castolin Eutectic 10-2006

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