Speed- Economy - Versatility

TEROMATEC 400
MODEL

PROCESS MANUAL AND SPARE PARTS LIST

 Table of Contents

SECTION 1 - TEROMATEC MODEL 400

1.1 Introduction 3
1.2 Electrical Shock 3
1.3 Personal Protection 3
1.4 Fire and Explosion Prevention 3
1.5 Ventilation 4
1.6 Standards and Safety-Related References 4

SECTION 2 - TEROMATEC PROCESS

2.1 Introduction 5
2.2 Advantages 5
2.3 TeroMatec Continuous Electrodes 7
2.4 TeroMatec Economics 7

SECTION 3 - TEROMATEC MODEL 400 WIRE FEEDER

3.1 Description 10
3.2 Technical Characteristics 10
3.3 Equipment Package 10
3.4 Controls and Process Indicators 10
3.5 Feed-Roll Assembly 11
3.6 Set-Up 12
3.7 Operation 12
3.8 Welding Procedure 13
3.9 Maintenance 14
- Trouble Shooting Flow Chart 17
- Electrical Diagram 18

SECTION 4 SPARE PARTS LISTS

4.1 Wire Feeder Spare Parts 19
4.2 TSG Torches 21
4.2.1 Technical Characteristics 21
4.2.2 Spare Parts 22
4.3 Bernard Gun Torch model 23

SECTION 5 WARRANTY 25
 SECTION 1 SAFETY
1.1 Introduction the equipment is connected to a power
source.
The operation and maintenance of any * When not welding, turn off the equipment.
welding equipment involves potential * Turn off the power source before servicing
dangers. Individuals who are unfamiliar with any part of the machine including gun and
welding equipment may, and can use, poor cable parts.
judgement due to lack of proper training. This
can cause injury to themselves and to others. WARNING: Electrical shocks can be fatal.
Operators are alerted to the following
potential hazards and the precautions 1.3 Personal Protection
needed so as to avoid possible accidents.
CAUTION: Ultraviolet light, sparks, and
READ AND UNDERSTAND THESE hot metal, can cause eye injury and skin
SAFETY PRACTICES BEFORE burns.
ATTEMPTING TO INSTALL, OPERATE OR
SERVICE THE EQUIPMENT.
* Do not look directly at na electric arc without
Throughout this manual cautions and proper protection.
warnings are used to describe situations * Always use a welding helmet. The table
which require additional care. below shows the recommended lens shades
for various amperage ranges:
CAUTION: Describes a situation which * Never weld without protective clothing:
may cause minor personal injury or gloves, safety shoes and hat.
damage to the equipment. * Make sure others are protected from
harmful arc rays.
WARNING: Describes a situation which * Wear ear plugs or other ear protective
may cause serious personal injury or devices when welding.
loss of life.
Arc Current Shade Value
1.2 Electrical Shock Up to 100 Amps N 08
100 to 200 Amps N 10
Voltages and amperages associated with 200 to 400 Amps N 12
welding can cause severe shock and burns Over 400 Amps N 14
to the body.
* Install and maintain equipment according
to all local electrical codes.
* Keep your body and clothing dry.
WARNING: Arc rays, sparks and hot metal
* Do not contact electrically live parts.
can cause eye injury and skin burns.
* Do not stand on, sit on, or lie on, any wet
surface when using welding equipment. 1.4 Fire and Explosion Prevention
* Proper grounding procedures must be
adhered to when using welding equipment.
* Do not use worn or damaged welding Hot slag or sparks can cause serious fires
cables or gun and cable assemblies. when in contac with combustible solids,
* Do not exceed the cables maximum rated liquids or gases.
current capacity.
* Keep all panels and covers in place when * Have fire extinguishers readily available

Page 3
in the working area.
* Remove all flammable and combustible WARNING:Gases and fumes can be
material from working area to a distance of dangerous to your health.
at least 35 feet.
* Do not weld containers that have held 1.6 Standards and Safety-Related
combustible liquids and/or gases. References
Containers must be thoroughly cleaned prior
For additional information, refer to the
to welding. (See section 1.6). following publications:
* Do not exceed the rated capacity of arc
* ANSI Standard Z49.1, Safety in Welding
welding equipment. It can overheat cables,
and Cutting
connectors and cause welding difficulties.
* Recommended safe practices for the
* Keep equipment clean, free of oil, grease
preparation for welding and cutting
and metallic particles. These can cause
containers that have held hazardous
short-circuits substances ANSI/AWS F4.1
Available from: American Welding Society,
WARNING: Fires and explosions can be 550 LeJeune Road, P.O. Box 351040, Miami,
caused by hot slag and sparks. FL 333135.
* OSHA, Safety and Health Standards, 29-
1.5 Ventilation CFR-1910
Available from: Superintendent of
CAUTION: Welding gases and fumes can Documents, US Government Printing Office,
cause discomfort and harm to your Washington, DC 20402.
health. Related Safety Equipment.

* Keep yourhead outof the fumes. Provide

adequate ventilation in the working area by
means of natural or mechanical ventilation.
The use of an Eutectic(r) Airlux(r) Fume
Eliminator is recommended for on-site
ventilation.
* Use an air-supplied respirator if ventilation
is not adequate to remove all fumes and
gases.
* Vapors of chlorinated solvents can form the
toxic gas phosgene when exposed to
ultraviolet radiation from an electric arc. All
solvents, degreasers and other sources of
these vapors must be removed from the
working area.
* Do not weld materiais containing Zinc,
Lead, Cadmium or Beryllium unless the
operator or anyone else exposed to the
fumes, is wearing approved respiratory
equipment or an external air-supplied
helmet.
* Should eyes, nose or throat irritation occur
during welding, this is an indication that the
ventilation is not adequate. Stop working and
take all necessary steps to improve
ventilation in the working area.

Page 4

SECTION 2 - TEROMATEC
PROCESS
2.1 Introduction
The TeroMatec Process is an
Eutectic+Castolin semi-automatic welding
system employing TeroMatec flux-cored
continuous electrodes, the TeroMatec Model
400 Wire Feeder (figre 1) and any
industrially-rated welding power supply
(either AC or DC). This welding process is
sometimes called open arc welding and
sometimes flux-cored arc welding.
Fig. 2.1 - Teromatec Wire Feeder
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 both in terms of metal
deposited per pound of electrode consumed
and in metal deposited per dollar; this means
that the TeroMatec Process is many times
more economical than stick electrodes since
the system deposits more material in less
time reducing labor costs by as much as
66%.
While the TeroMatec Process is not as
versatile as manual welding - it does not
have the all-position capability and it is not
as portable - it is, however, more versatile
than other high-deposition systems such as
submerged arc welding, GMA welding, and
fully automatic systems.
The TeroMatec Process can be used
anywhere in the field or in the shop. It creates
its own shielding gas which is not affected
by wind as GMAW systems are and does
not require a gas supply.
The speed, the economy and the versatility
of the TeroMatec Process makes it uniquely
suited for applying TeroCote wear protection
over very large areas. Eutectic+Castolin also
offers TeroMatec continuous electrodes for
joining applications. The ECT Electrodes are
showed at figure 2.
Fig. 2.2 - Teromatec Process
2.2 Advantages
Specific details on the economics associated
with the TeroMatec Process are given in this
Section (2) and operating features are
described in Section 3. The following listing
is a summary of the advantages and features
of the process.
Non-Stop Welding: The electrode is fed
continuously through the gun and cable
assembly so that welding is non-stop.
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Fast Deposition: It is possible to achieve Electrode Diameter Amperage Range
deposition rates of over 20 pounds of metal 1/16" 150 - 200
an hour with the TeroMatec Process. It is up 3/32" 225 - 300
to four times faster than manual arc welding. 7/64" 275 - 375
High Deposition Efficiency: While deposition
efficiencies (ratio of weight of metal is less and labor costs are less than
deposited to electrode weight) vary with the equivalent stick electrodes of similar
electrode used and other operating factors, analysis.
TeroMatec continuous electrodes
customarily exhibit efficiencies over 85% Trouble-Free Operation: Unlike fully
versus perhaps 60% for a coated mild steel automatic and GMAW systems, the
stick electrode. TeroMatec equipment is simple to operate
and maintain - it is virtually trouble-free.
No Stub-Loss: About 2 inches of every 14- There are only two adjustments: roll pressure
inch stick electrode is thrown away - a 14% and wire feed rate (arc length).
loss. With the TeroMatec Process there is
no stub loss. Wide Range of Applications: There are
TeroMatec continuous electrodes for both
No Gas Supply Required: Since TeroMatec joining and for TeroCote(r) applications.
electrodes generate their own shielding gas,
no external gas supply is required, reducing Low Cost: Compared to the other high-
operating costs. deposition systems, the TeroMatec Model
400 Wire Feeder (the only auxiliary
Lower Labor Costs: Combining non-stop equipment needed for the process) is much
welding and a faster deposition rate means less expensive to buy and to operate.
labor costs can be cut 66% or more with TeroMatec continuous electrodes, because
theTeroMatec Process. Deposits produced of automated manufacturing, cost less per
by spray transfer are smooth and flat, pound than equivalent alloys for manual arc
requiring less machining - another labor- welding.
saving feature.
Equipment Required: The only equipment
Versatility: The TeroMatec Model 400 Wire required to adapt any industrially-rated
Feeder weighs only 53 pounds - a truly welding power supply for the TeroMatec
portable unit. All the versatility and visibility Open Arc Welding Process is a TeroMatec
of manual arc welding are preserved with Wire Feeder and a coil of TeroMatec
the TeroMatec Process - welders and follow continuous electrode wire. The power supply
contours and control weld deposits easily. can be either AC or DC, with aminimum duty
cycle of 60% and a wlding current range
Low Heat Input: Although much higher according to the electrode diameter selected:
amperages are used in the TeroMatec
Process, the higher deposition rate permits
higher travel speeds so that the heat
concentration and thus dilution of the base Type Typical Hardfacing Typical TeroMatec
metal, is easier to control. Electrode Electrode
Deposited alloy
Less Clean-up Time: Since the core of by area
45% 75%

TeroMatec continuous electrodes contains Deposited alloy

76% 85%
by weight
a minimum amount of flux, there is less slag
to remove. With normal stick-out, there is
very little spatter. Therefore, clean-up time

Page 6
2.3 TeroMatec Continuous 2.4 TeroMatec Economics
Electrodes
TeroMatec continuous electrodes consist of
a metallic sheath containing a mixture of flux,
deoxidizing elements and alloying elements.
This flux serves to:
a. Provide a shielding gas
b. Act as deoxidizers to help clean and
produce porosity-free weld metal
c. Form slag on the molten weld pool to
protect it from atmospheric gases during
solidification
d. Act as an arc stabilizer to obtain a smooth
welding arc and reduce spatter
e. Add alloying elements to the weld metal
to improve weld deposit characteristics.
The figure 2 show a ECT wire in process.
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. In comparison to a typical hard-
facing stick electrode:
Since TeroMatec electrodes contain 30%
more metal per inch of electrode, they deliver
30% more metal per inch of electrode
consumed. And because they contain
considerably less flux, they deliver more
weld metal per pound.
TeroMatec flux-cored electrodes are inside-
out electrodes; the metal is on the outside
and the flux, which contains alloying
elements and the shielding gas generating
elements, inside the wire. The heat
generated by the arc vaporizes the flux
constituents which are directed toward the
molten weld pool by the tubular sheath to
produce either a modified globular or a
spray-type metal transfer within a gaseous
envelope.
Note: Gas Metal Arc Welding (GMAW) is
the now preferred term to MIG.
Manual arc welding is the most economical
welding process to use on small-to-medium
jobs requiring different alloys, and the
TeroMatec Process is the most economical
process for large jobs. The problem then
arises: what classifies a job as large? Where
is the break-even point? The purpose of this
section is to present the economic factors
that must be considered in making the
decision as to which of these two processes
to use.
Comparisons are made between manual arc
welding (Shielded Metal-arc Welding) and
TeroMatec open arc welding with flux-cored
electrodes. Both these techniques are
considered suitable for general purpose
applications commonly found in
maintenance and repair facilities. Other
techniques such as submerged arc, GMAW
and electroslag are not included in the
comparisons, since they are considered
processes for more specialized production-
type applications. The very size of the
applications being considered excludes the
use of the oxy-acetylene process from
consideration.
Fig.2.3: Comparison of Typical Deposition Rates for
Some Common Welding Processes
Page 7
Labor Factors
The labor factors to be considered are:
- preparation time Variations in arc length caused by the
- the amount of material that can be welders manipulation of the gun produce
deposited over na extended period of time variations in voltage, affecting the deposition
- the amount of time required to clean up. rate. The TeroMatec Wire Feeder is
designed to automatically compensate for
Set-up time to load a TeroMatec Model 400 such variation in voltage - arc length remains
Wire Feeder with a coil of electrode wire, constant - welding is uninterrupted.
feed the wire through the gun and cable
assembly, and adjust the feed rate only Clean-up time is the third cost factor.
requires a few minutes, but it becomes a time TeroMatec electrodes contain much less flux
consuming factor if the electrode must be than flux-coated electrodes, approximately
changed frequently. Once set up, however, 35% less by weight. It is the gas generating
TeroMatec continuous wire electrodes can constituents in the core that protect the weld
(theoretically) be deposited for hours, deposit. Consequently, there is less slag to
stopping only to replace the coil. Stick clean and, therefore, less clean-up time is
electrodes, on the other hand, are replaced required. What slag there is, is easily
after 12-13 inches of electrode has been removed.
used. Replacement requires stopping,
flipping the mask, reloading the electrode Material Costs: Two factors must be
holder, resetting the mask and relocating the considered when estimating material costs:
weld bead, before resuming welding. cost per pound of metal deposited and stub
loss.
A comparison of the deposition rates for a
7/64-inch diameter TeroMatec continuous Generally speaking, TeroMatec electrodes
electrode (more or less the industry standard having equivalent alloying constituents are
size) with various sizes of typical low alloy priced less than their stick electrode
stick electrodes can be made using the chart counterparts. This is primarily because of
shown in Figure 2.2. This chart shows savings inherent in the manufacturing
dramatically how much more metal is process and in packaging considerations.
deposited by the TeroMatec Process Add to this the fact that there is more flux
electrode for a given increase in current. per pound in stick electrodes, and the
inevitable result is that a TeroMatec
The non-stop welding feature is the most electrode delivers more weld metal for the
important factor in reckoning labor costs. same money amount.
With the TeroMatec Process, welding can
continue without lifting the electrode from the In addition, consider stub loss. Estimate the
weld bead until the job is done. Most welding length of discarded stubs; two (2) inches
authorities agree that this factor alone makes minimum and more likely 3 to 3.5 inches of
open arc welding three (3) times faster than every 14-inch electrode is thrown away;14%
manual arc welding, reducing labor costs by to 25% of the electrode is not used.
a significant 66%.

Continuous welding is only possible if the

electrode feed rate is equal to the electrode
deposition rate; otherwise, the electrode will
either contract into the gun handle,
extinguishing the arc, or stick-out will
increase causing erratic arc action.

Page 8
In summary, for those applications requiring
the use of a single alloy, the TeroMatec
Process has an economic advantage over
stick electrodes, even on small-to-medium
size jobs. Where it is necessary to change
electrodes to meet the requirements of
different repair and maintenance tasks, the
area to be covered becomes the decisive
factor.

TeroMatec electrodes are suitable for limited

out-of-position work. However, they do not
have the same all-position versatility of stick
electrodes.

It should be remembered that the same

welding machine can be used for both stick
electrodes and TeroMatec Process, by
simply bypassing the TeroMatec Model 400
Wire Feeder with a standard electrode cable.
This arrangement permits the use of manual
arc welding when convenient and the
TeroMatec Process when necessary, without
connecting and disconnecting any leads or
cables.

Page 9
SECTION 3 - TEROMATEC
MODEL 400 WIRE FEEDER 3.3 Equipment Package

3.1 Description The standard equipment package appears

in figure 3.1 and shows:
The TeroMatec Model 400 Wire Feeder was
designed to feed continuous wire electrodes
as either a semi-automatic or fully automatic
open arc welding process.

The equipment is highly versatile and can

operate when connected to any constant
Current welding power supply (AC or DC).
The TeroMatec Model 400 Wire Feeder is
capable of operating with 7/64", 3/32" and
1/16" diameter electrodes.

The TeroMatec Model 400 Wire Feeder has

a voltage sensor which controls the welding
current and wire feed rate. This helps to
maintain a constant arc length for a pre-set
voltage/wire speed.

The equipment is easy to operate. Wire

feeding starts when the arc is struck and Fig. 3.1 - Standard Equipment
stops whenever the arc is interrupted. The
remote control unit allows the operator to * Wire feeder assembly
control the motor on/off mode, as well as both * Welding gun with 10 feet (3.0m) insulated
the forward and reverse wire inching mode cable
from his work station. * Insulated ground cable, 15 feet (4,5m)
* Coil spider
3.2 Technical Characteristics
The next table will show the Wire Feeder Options: - Caster wheels
characteristcs and the power source - Spool adapter
requirements
3.4 Controls and Process Indicators
Welding current range 100 to 400 Amps
Nominal welding current 400 Amps
Duty Cycle 100% Note: Refer to wire feeder mounting board
Mains Voltage +/- 10% 78 V; AC or DC Current (Fig.3.2)
Open circuit voltage The same of power source
Constant Current AC or
Welding power source required
DC
Welding power source open
Maximum 80 V
circuit voltage
Nominal motor supply 28 VDC maximum
Motor power input 1/8 HP (95 W)
Wire feed speed (at 28 VDC) 40 ft/min (12 m/min)
1/16 (1,6 mm)
Applicable wire diameter 3/32 (2,4 mm)
7/64 (2,8 mm)
Coil weight Maximum 60 lb. (27 kg)
Weight without cables 53 lb. (24 kg)
1,84 x 0,83 x 2,73 ft
Dimensions (L x W x H)
(560 x 255 x 835 mm)

Figure 3.2 - Controls on the Wire Feeder

Page 10
a. Wire Feed Speed Control: Adjusts wire
speed rate. Can be asjusted to increase or
decrease electrode feed speed during
welding.
b. Power Indicator Light: During inching this
lamp indicates that power is available tothe
drive motor. Note that the lamp will show off
during welding.
c. Roll Pressure Adjustment Knob: Used to
exert pressure on the electrode.
d. Coil Adapter Tension Adjustment: This
tensions the adapter to prevent uncoiling
during feeding and/or welding.
e. Power Input Terminal: Power cable
connection from the power supply.
f. Circuit Breaker: This protects against
overload and should always be kept locked
in. Because this item is thermally sensitive
it may not reset immediately after opening.
Figure 3.3 - Remote Control Unit
Allow a few minutes to elapse, then reset.
3.5 Feed-Roll Assembly
Remote Control Unit (Refer to Fig. 3.3)

a. On-off switch: This controls the input This assembly consists of four identically
power to the wire feeder. knurled discs and one spacer which permits
the use of all three diameters. Each knurled
Caution: The electrode is still electrically disc is market 3/32" on one face and 1/16"
live when the input power switch is in on the opposite. A combination of knurled
the off position. discs and spacer allows the use of all three
wire diameters. Figure 3.4 shows the
b. Inching switch: This is a maintained on assembly for each electrode diameter.
and maintained off switch. Note: It is not a
momentary switch. It is used to feed the
electrode wire through the gun and cable
assembly during set-up. In the forward
position, wire moves from the feeder to the
gun and, in the reverse position, wire is
retracted.

Note: The switch is automatically

disconnected from the circuit during
welding.

Fig. 3.4 - Disk assembly

Page 11
3.6 Set-Up Negative)
Warning: During set-up of the TeroMatec
Model 400 Wire Feeder, the power supply
must be off.
* Position the TeroMatec Model 400 Wire
Feeder in such a manner that the gun and
cable assembly will reach the workpiece with
a minimum of bending.

Figure 3.4: Set-up for 7/64" (2.8mm), 3/

32"
(2.4mm) and 1/16" (1.6mm) wires.

* Connect the positive cable from the power

supply output to the power input terminal on
the wire feeder.
* Connect both the negative cabel (DCEN)*
from the power supply and wire feeder
ground cable to the workpiece.
Figure 3.5 - Gun and Cable Connection
Warning: Select a suitably sized welding
cable according to the welding current. Caution: Make sure that the wire end is
Do not overload welding cables. free from burrs and has no rough edges
or bends that could obstruct wire feeding.
* Unscrew the gun nozzle and contact tip.
Make sure that the liner is correct for the * Feed the wire into the entry and exit guide
selected electrode diameter tubes.
* Connect the torch to the wire feeder. * Return the upper-roll to its normal position
Loosen the feed cable Allen-head screws on and tighten the locking nut by about a 1/4 of
the wire feeder base plate, insert Feeder a turn. Adjust if necessary to prevent wire-
Adapter and re-tighten screws (Fig. 3.5). drive slipping.
* When using coils of wire secure the coil
with the four dogs on each spider leg. Caution: Excessive feed-roll pressure
may cause deformation of wire. Should
Caution: Do not remove the wire or tape the feed-roll pressure be insufficient,
on the coil, otherwise the wire could slippage will occur.
uncoil and bird nest
* Remove tape (or wire) from the coil or spool
* When using spools of wire, remove the as necessary.
spider mount and install spool mount
adapter. 3.7 Operation
* Turn on the power supply.
Caution: Do not remove the wire or tape
on the plastic spool, otherwise it could Warning: In this situation the base plate,
uncoil. all metallic parts, including feed rolls,
power connector and electrode are
* Loosen the roll pressure adjustment knob, electrically live with an impressed OCV*
lift the upper-roll bracket and hold it in from the power supply. Do not allow these
position using the upper-roll locker. parts to touch the workpiece - electrode
*(DCEN = Direct Current Electrode exempted during welding.

Page 12
 operation in the following ways:
* Set wire feed speed to position 5 for a. High voltage (long arc length) increases
inching. Make sure that during inching the spatter and porosity and spreads (flattens)
electrode does not contact workpiece or work the weld bead producing an irregular
table. contour. However, high voltage combined
Warning: An electric arc will start if the with higher current will reduce porosity and
electrode makes contact with the produce a more desirable weld bead.
workpiece or work table. b. Low voltage produces a convex weld bead
contour and excessive ripple. Very low
* On the remote control unit, set on-off voltage will cause the Wire Feeder to drive
switch to ON. Press inching control to the electrode into the work where it may stick,
forward. Wire will start feeding into the torch. extinguishing the arc.
*(OCV = Open Circuit Voltage)
* Always watch the electrode unsinding. If it
starts to unravel faster than the feed
required, adjust the spider tension to prevent
unravelling.
* Hold the switch in the forward position
until about 2" of electrode emerges from the
gun, then reset switch.
* Turn off power supply and wire feeder.
* Select a contact tip having the same
diameter as the electrode. Thread it over the
electrode and tighten it in place on the gun.
Replace nozzle and tighten finger-tight. Fig. 3.7 - Voltage influence
* Turn on power supply and set proper Arc Current Effects
welding current.
* Turn on wire feeder. Arc current variations produce the following
* Select a piece of metal and strike an arc.
effects (provided that all other factors are
Adjust the wire feed speed so that the wire
held constant).
feed rate matches the deposition rate of the
a. High current produces flat weld beads and
electrode being used. increase melting rate, deposition rate and
* Strike electrode on the workpiece to start
penetration of the base metal. There is
welding. Adjust wire feed/voltage to optimize
excessive penetration and a tendency
welding conditions. toward spatter. Increasing the current
* To stop welding break arc with a rapid side
permits the use of higher voltages without
or upper-hand motion. causing weld bead porosity and increased
wire feed speed.
3.8 Welding Procedure b. Low current produces a narrow, high
contour bead with low penetration. This is
The TeroMatec Process variables are arc an advantage on thin metals (less than 1/
voltage and current, travel speed and 4", where control of penetration is highly
electrical stick-out. desirable.
Note: Stick-out is the distance from the tip of the
electrode to the contact tip in the gun and cable
assembly. The contact tip is the electrical contact
Torch Travel Speed Effects
for the electrode.
Travel speed variations cause:
Arc Voltage Effects a. When travel speed is too high, there is
shallow penetration and weld beads with
Arc voltage variations affect the welding uneven edges. There is a tendency toward

Page 13
increased spatter.
Fig. 3.8 - Current influence
b. When travel speed is too slow, penetration
is excessive, slag inclusions become a Warning: Always turn off the wire feeder
problem and the weld bead pattern will and disconnect welding equipment from
become rough and irregular. the power source before servicing.
Fig. 3.9 - Travel speed influence
Stick Out Effects
Electrical Stick-out should be about 2 inches
(50mm) for most TeroMatec electrodes for
best arc stability. If stick-out is too short,
welding current will increase and there is
greater penetration of the base metal; spatter
will also build-up on the contact tip.
a. When the stick out is to long, the electrode
becomes of difficult control, resulting in a
great amount of spaters and irregular arc.
b. When the stick out is very short, the
welding current rise, with consequent
increase of the penetration and accumulation
of spaters in the contact tip and nozzle.
Positions of Welding
Out-of-position welding is more difficult with
open arc welding than with manual arc
welding because the high deposition rate
produces large, fluid weld pools. Using DC
electrode positive (DCEP) and the lowest
current densities recommended for the
electrode, ou-of-position capability can be
improved. Also, some TeroMatec electrodes
are better suited for out-of-position welding
than others.
3.9 Maintenance
A. Preventive Maintenance
Under normal working conditions, the
TeroMatec Model 400 Wire Feeder should
be serviced at least twice an year. This
preventive maintenance is in two stages:
A.1 Gun & Cable Assembly
Caution: If the wire is jammed or fused to
the nozzle, cut the wire at the feed-roll
end.
* Remove the gun and cable assembly by
loosening the feeder adapter Allen-head
screws.
* Remove torch insulator and brass adapter.
* Remove feeder adapter and wire guide
tube.
* Remove liner and check for signs of wear.
If there are signs of wear, replace the liner.
Coat the liner with RotoLube(tm) or some
other dry lubricant such as Molybdenum
disulphide before replacing. It is generally
easier to replace the liner from the head
because of the curved gun body. To facilitate
reassembly, stretch the cable flat.
* Check nozzle and contact tip. If there are
signs of wear or damage, replace.
* Refit contact tip and nozzle.
Page 14
A.2 TeroMatec Model 400 Wire Feeder * Reassemble the feed-roll mechanism.
* Check the spider assembly for excessive
* Remove electrode wire and Gun and Cable play.
Assembly.
* Remove the wire feeder back cover by
loosening the four screws.
* After the cabinet is open, use compressed
air at low pressure to remove dust and grit
that may have accumulated.
* Clean the current relay contacts with cloth
strips soaked with electrical cleaner/lubricant
(Fig. 3.10).

Fig. 3.11 - Feed roll remove

* Remove the spider assembly, check the

insulator for wear, clean it, add a little
lubricant and reinstall. You should do the
same if you are using the spool mount
adapter.

Fig. 3.10 - Relay contacts

* Check the wire feed speed rheostat for

cleanliness and proper wiper contact motion.
* Check all electrical connections. Make sure
they are mechanically tight.
* Check wiring for any broken or defective
insulation.
* Reclose the cabinet.
* Remove both feed-rolls by removing the
feed-roll shoulder bolts (Fig. 3.11).
* Check gear teeth visually for wear.
* Check the knurled area of the feed-rolls. If
they are worn smooth replace the rolls. If
Fig. 3.12 - Knurled disk remove
they are dirty or have compacted dirt, clean
with a wire brush. B. Electrical Problems
* The knurled discs may be separated from
the gear section by removing the two Allen- Please refer to the attached block and
head screws (Fig. 3.12). electrical diagram (Fig. 3.12).For erratic wire
* Clean the Feed-Roll Assembly and wash feed check using the following procedure:
the bearings in a suitable solvent. Apply * Hand-feed a length of wire through the Gun
fresh lubricant to the bearings and check and Cable Assembly to determine if there is
freedom of movement. excessive restriction or obstruction. To

Page 15
reduce restriction in the cable, clean out with
air hose and use a small amount of dry
lubricant.
* Slippage in feed-rolls:
- Too little feed-roll pressure.
- Too much feed-roll pressure, causing wire
deformation and binding in the welding tip.
- Feed-roll built-up with foreign material.
Clean or replace, if worn.
* Check for even, steady wire pay-off from
the coil or spool.
* The contact tip and nozzle should be
checked for spatter, wear or obstruction.
Wire should feed freely through the Gun and
Cable Assembly.
* Check the feed-rolls for smooth operation.
Erratic operation could be caused by poor
electrical connections or by damage to the
drive rolls. All electrical connections and
parts should be checked.

On the next pages, the figures 3.13 and 3.14

will show a trouble shooting guide, useful to
detect errors and solutions and the
electrical diagram

Caution: Over-heated cables or

connections are a sure sign of trouble.
Replace all worn or frayed cables and
repair or replace connections as required.

Page 16
Trouble Shooting Flow Chart

Page 17
Electrical Diagram

Page 18
 SECTION 4 SPARE PARTS LISTS
4.1 Wire Feeder Spare Parts

02
10

03

04
09

07 05 01
06

08

20
14
25
27
19 23
11 12 13 15 16

26
17 18 22

24
32 34
31

38
33
30

36
29

35

37
21
28

Page 19
Pos. Old Code New Code Description
01 23C03833 0.550.124.880.022 Chassis set
02 23G01782 2.237.017.820.423 Cabinet set
03 23T05380 2.232.053.800.601 Mechanism cover
04 22B30832 2.222.308.320.423 Protecting rubber
05 22C14858 2.223.148.580.411 Remote control
06 22C14904 2.223.149.040.423 On / Off switch
07 22C14912 2.223.149.120.417 Reversible Switch
08 22P10400 2.227.104.000.510 Rubber foot (unit. Code)
09 29C00160 2.293.001.600.419 Earth cable
10A 29C00097 2.293.000.970.412 Crosspiece complete kit
10B 29C00100 2.293.001.000.402 Crosspiece only
11 27A03634 2.271.036.340.427 Washer squeeze
12 27B03787 2.272.037.870.402 Axis insulate bush
13 27A03626 2.271.036.260.402 Support washer
14 29B00360 0.550.431.880.030 Mobile arm
15 27E02601 2.275.026.010.406 Support axis
16 29A00209 2.291.002.090.412 Insulate washer
17 29A00194 2.291.001.940.400 Cotter washer
18 22M12078 2.224.120.780.509 Squeeze spring
19 29A00179 2.291.001.790.419 T washer
20 29A00225 0.550.422.880.023 Coil adapter
21 27T03706 2.272.037.060.626 Back cabinet cover
22 23G01278 2.237.012.780.429 Wire guide kit
23 22K10050 2.222.100.500.502 Wire speed adj. Button
24 27E02440 2.275.024.400.426 Pinion Gear
25 22L01020 2.223.010.200.521 Neon lamp
26 29M01055 2.294.010.550.512 Mechanism complete
27 27P02082 2.277.020.820.510 Front panel
28 22R15568 2.229.155.680.518 Feed roll set
29 27D00981 2.274.009.810.423 Knurled Feed roll 1/16 x 3/32
30 27D00990 2.274.009.900.424 Spacing Disk
31 22D10016 0.550.339.001.000 Circuit Breaker 5A
32 23P02460 2.237.024.600.527 Rectifier bridge
33 22R31105 2.229.311.050.529 Resistor 4R7 100 W
34 22R11121 2.229.111.210.513 Resistor 10R 100W
35 22R10400 2.229.104.000.519 Power relay 30A
36 23B01704 2.232.017.040.428 Relay coil
37 22M00053 2.224.000.530.530 Motor reducer complete
38 22R10469 2.229.104.690.506 Rheostat 5R 150W

Page 20
4.2 TSG Torches

4.2.1 - Technical Characteristics

Characteristic Values
Model TSG 310 TSG 610
Head Weight (kg) 1,1 1,6
Wire diameter (mm) 1,6 1,6 to 2,8
Nominal current at 100% duty cycle (A) 240 350
(1)
Wire diameter application
1/16 (1,6 mm) *** *
3/32 (2,4 mm) N.A. ***
7/64 (2,8 mm) N.A. ***
(1) Recommendations description: N.A. = Not applicable ; (*) = Can be used
for specific application; (***) = Recommended to general use

Page 21
4.2.2 TSG Torches Spare Part List

07
06 08

08
05
04

09
02 03 09

01

10 11
10

14 13
12

Item Code
Pos. Description
TSG 310 Torch TSG 610 Torch
Teromatec Torch set 2.222.106.900.619 2.222.103.210.609
01 Nozzle 2.222.021.890.430 2.222.021.890.430
02A Contact tip 1/16 2.222.011.900.412 2.222.011.900.412
02B Contact tip 3/32 2.222.003.560.402 2.222.003.560.402
02C Contact tip 7/64 2.222.003.640.427 2.222.003.640.427
03 Tip support 2.227.016.650.528 2.227.016.650.528
04 Insulator 2.229.010.870.420 N.A.
05 Micro gun 2.224.007.890.505 2.224.002.740.527
06 Micro gun insulator 2.229.010.950.414 N.A.
07 Insulator washer 2.223.012.090.511 N.A.
08 Torch hilt 2.227.105.830.520 2.227.019.160.518
09 Hand protector N.A. 2.227.016.730.522
10 Protector clamp N.A. 0.252.900.415.001
11 Current cable 2.223.034.900.412 2.223.046.070.419
12 Back assembly cable 2.224.007.970.530 2.224.016.690.527
13 Teromatec adapter 2.221.001.730.403 2.221.001.730.403
14A Liner 1/16 2.227.013.630.421 2.227.013.630.421
14B Liner 7/64 N.A. 2.223.011.950.506
Obs: N.A. Not applicable

Page 22
4.3 Bernard Gun model ez 4610 torch

This torch model accompanied the TEROMATEC System produced in the Brazil and
exported by the Eutectic-USA. This model was descontinued in Brazil in 1997. For a
complete list of spare part, contact Eutectic - USA or Bernard Guns Distributors.
Nowadays, the standardized torches are TSG models.

06

07

03 04
05

01
02

Item Old Code New Code Description

23P02444 2.237.024.440.508 Bernard gun model EZ 4610 with adapter
01 22B00160 2.222.001.600.425 Nozzle
02A 22B02235 2.222.022.350.411 Contact tip 3/32" (2,4mm)
02A 22B02227 2.222.022.270.417 Contact tip 7/64" (2,8mm)
03 22P01649 2.227.016.490.509 Gas diffuser
04 22I01079 2.229.010.790.426 Insulator
05A 22G01266 2.227.012.660.424 Liner 1,6mm
05B 22G01274 2.227.012.740.418 Liner 2,8mm
06 22E05157 2.225.051.570.403 Bernard gun adapter
07 22A00092 2.221.000.920.425 Aluminum basis adapter

Page 23
SECTION 5 WARRANTY
This equipment is warranted only against defects in design, materials and workmanship
for a period of one year calculated from the date of invoice and subject to the conditions
detailed below:

CONDITIONS

1. This warranty is personal to the original user, is not transferable and shall not be valid
unless the equipment was purchased or taken on extended loan terms from an
Eutectic+Castolin Group Company.

2. This warranty will be invalidated if the equipment is misused or modified in any way
without the written consent of the Company or if any original component or accessory has
been replaced by any component or accessory of a type not recommended or approved
by the Company, or if operated other than in accordance with the instruction Manual.

3. Any claims made under this warranty must be made to the Company. The cost of
transportation to and from the Dealer must be paid by the customer.

4. In the event of the equipment being returned which on test is found to comply with
published specification, the Company reserves the right to charge a reasonable fee for
testing the equipment and for return transportation.

5. The liability of the Company under this warranty shall be limited to the cost of repair or
complete replacement (at the discretion of the Company) of the defective equipment. The
Company shall not be liable for any incidental or consequential damages for any breach
of warranty.

6. The Company does not accept responsibility for any loss or damage during transit to or
from the Dealer or the Company, but every effort will be made to investigate complaints of
loss or damage if these arise.

7. Motors, motor brushes, nozzles, and tips are consumable parts and are not covered by
this warranty.

8. Contact your Castolin products distributors or Castolin Local Company for attendance.

Page 24