Derby 425 DS

OPERATING MANUAL / SPARE PARTS LIST

 Dear Castolin customer

This brochure is intended to familiarise you with how

to operate and maintain your Derby 425 DS.. You will
nd it well worthwhile to read through the manual
carefully and to follow all the instructions it
contains. This will help you to avoid operating errors
and the resultant malfunctions. Your machine will
repay you by giving you constant operational readiness
for many years to come.

Warning! The machine may only be put into

service by trained personnel, and only in ac-
cordance with the technical directions. Before
you start using the machine, you must read the
section headed Safety rules.

Inhaltsverzeichnis

Safety rules 4 Starting to use the weldingmachine 8

General remarks 4 Utilisation for intended purpose only 8
Utilisation for intended purpose only 4 Machine set-up regulations 8
Obligations of owner/operator 4 Mains connection 8
Obligations of personnel 4 Unit assembly 8
Personal protective equipment 4 Assembly of the unit with the water cooler 8
Hazards from noxious gases and vapours 4 Torch connection 10
Hazards from ying sparks 4 Loading of the welding wire 10
Hazards from mains and welding current 4 Gas cylinder installation 10
Particular danger spots 5
Informal safety precautions 5 MIG/MAG welding with gas 11
Safety precautions at the installation location 5 Setting the operating point 11
Safety precautions in normal operation 5
Safety inspection 5 MIG/MAG welding without gas 11
Alterations to the welding machine 5
Spares and wearing parts 5 Care and maintenance 12
Calibration of welding machines 5
CE-marking 5 Troubleshooting Guide 16
Guarantee 5
Copyright Technical Data 16
6
General remarks 6
Principle of the Derby 425 DS 6
Machine concept - Derby 425 DS 6

Front and back panel description 7

Operating modes 7
2-step mode 7
4-step mode 7
Safety rules
General remarks
This welding machine has been made in accordance
with the state of the art and all recognised safety rules.
Nevertheless, incorrect operation or misuse may still
lead to danger for
the life and well -being of the welder or of third
parties,
the welding machine and other tangible assets
belongingto the owner/operator,
efcient working with the welding machine.
All persons involved in any way with starting up,
operating,servicing and maintaining the welding ma-
chine must
be suitably qualied
know about welding and
follow exactly the instructions given in this manu-
al.
Any malfunctions which might impair machine safety
must beeliminated immediately.
Its your safety thats at stake!
Utilisation for intended purpose only
The welding machine may only be used for jobs as de-
ned by the Intended purpose (see the section headed
Starting touse the welding machine).
Utilisation in accordance with the Intended purpo-
se also comprises
following all the instructions given in this manual
performing all stipulated inspection and servicing
work
Obligations of owner/operator
The owner/operator undertakes to ensure that the only
personsall owed to work with the welding machine are
persons who
are familiar with the basic regulations on work-
place safety and accident prevention and who have
been instructed in how to operate the welding
machine
have read and understood the sections on safety
and thewarnings contained in this manual, and
have conrmed asmuch with their signatures
Regular checks must be performed to ensure that per-
sonnelare still working in a safety-conscious manner.
Obligations of personnel
Before starting work, all persons entrusted with car-
rying outwork on the welding machine shall undertake
to observe the basic regulations on workplace safe-
ty and accident prevention
to read the sections on safety and the warnings
contained in this manual, and to sign to conrm
that they haveunderstood these
Personal protective equipment
For your personal safety, take the following precauti-
ons:
Wear stout footwear that will also insulate even in
wetconditions
Protect your hands by wearing insulating gloves
Protect your eyes from UV rays with a safety shield
containing regulation lter glass
Only use suitable (i.e. ame-retardant) clothing
Where high noise levels are encountered, use ear-
protectors
Where other persons are nearby during welding, you
must
instruct them regarding the dangers,
provide them with protective equipment and/or
erect protective partitions or curtains.
Hazards from noxious gases and vapours
Extract all fumes and gases away from the work-
place, usingsuitable means.
Ensure a sufcient supply of fresh air.
Keep all solvent vapours well away from the arc
radiation.
Hazards from ying sparks
Move all combustible objects well away from the
welding location.
Welding must NEVER be performed on containers
thathave had gases, fuels, mineral oils etc. stored in
them. Evensmall traces of these substances left in
the containers area major explosion hazard.
-Special regulations apply to rooms at risk from re
and/orexplosion. Observe all relevant national and
international regulations.
Hazards from mains and welding current
An electric shock can be fatal. Every electric shock
ishazardous to life.
Magnetic elds generated by high amperages may
impairthe functioning of vital electronic devices
(e.g. heart pacemakers). Users of such devices
should consult their doctors before going anywhe-
re near the welding workplace.
All welding cables must be rmly attached, unda-
maged andproperly insulated. Replace any loose
connections andscorched cables immediately.-
Have the mains and the appliance supply leads
checkedregularly by a qualied electrician to ensu-
 re that the PE conductor is functioning correctly.
Before opening up the welding machine, make
absolutelysure that this is dead. Discharge any
components thatmay store an electrical charge.
If work needs to be performed on any live parts,
there mustbe a second person on hand to switch of
the machine at themain switch in an emergency.
Particular danger spots
Do not put your ngers anywhere near the rotating
toothed wheels of the wirefeed drive.
Special regulations apply to rooms at risk from re
and/orexplosion. Observe all relevant national and
internationalregulations.
Welding machines for use in spaces with increase-
delectrical danger (e.g. boilers) must be identied
by the S(for safety) mark.
Welding-joins to which special safety requirements
apply must only be carried out by specially trained
welders.
When hoisting the power source by crane, always
attach the chains or ropes to the hoisting lugs at
as close an angle to the vertical as possible. Before
hoisting, remove the gascylinder and the wirefeed
unit.
When hoisting the wirefeed unit by crane, always
use aninsulating suspension arrangement.
Informal safety precautions
The instruction manual must be kept at the wel-
ding machine location at all times.
In addition to the instruction manual, copies of
both the generally applicable and the local accident
prevention andenvironmental protection rules
must be kept on hand, andof course observed in
practice.
All the safety instructions and danger warnings
on the welding machine itself must be kept in a
legible condition.
Safety precautions at the installation location
The welding machine must be placed on an even,
rm oor in such a way that it stands rmly. A
welding machine that topples over can easily kill
someone!
Special regulations apply to rooms at risk from re
and/orexplosion. Observe all relevant national and
internationalregulations.
By means of internal instructions and checks, ensu-
re thatthe workplace and the area around it are
always kept cleanand tidy.
Safety precautions in normal operation
Only operate the welding machine if all its protecti-
ve featuresare fully functional.
Before switching on the welding machine, ensures
that nobody can be endangered by your turning on
the machine.
At least once a week, check the machine for any
damage that may be visible from the outside, and
check that the safety features all function correctly.
Safety inspection
The owner/operator is obliged to have the machine
checked for correct functioning by a trained electrician
after any alterations, installations of additional com-
ponents, modications, repairs, care and maintenance,
and in any case at least every six months.
In the course of such inspection, the following regulati-
onsmust be observed (as a minimum):
VBG 4, 5 - Electrical plant and apparatus
VBG 15, 33 / 49 - Welding, cutting and allied
processes
VDE 0701-1 - Corrective maintenance, modication
and testing of electrical equipment
Alterations to the welding machine
Do not make any alterations, installations or modi-
cationsto the welding machine without getting
permission from themanufacturer rst.
Replace immediately any components that are not
in perfectcondition.
Spares and wearing parts
Use only original spares and wearing parts. With
partssourced from other suppliers, there is no
certainty thatthese parts will have been designed
and manufactured to cope with the stressing and
safety requirements that will bemade of them.
When ordering spare parts, please state the exact-
designation and the relevant part number, as given
in thespare parts list. Please also quote the serial
number of yourmachine.
Calibration of welding machines
In view of international standards, regular calibration
of welding machinery is advisable. Castolin recom-
mends a 12-month calibration interval. For more infor-
mation, please contact yourCastolin partner!
CE-marking
The welding machine fulls the fundamental require-
ments ofthe Low-Voltage and Electromagnetic Compa-
tibility Directive and is thus CE-marked.
Guarantee
The guarantee period is 12 months and applies to sing-
le-shift operation, provided that the equipment is used
properly.
The guarantee covers the costs for replacement parts
and component groups including assembly time. The
guarantee does not cover wear and tear of components
due to operation. Improper use of the equipment inclu-
ding damage caused byforce invalidates the guarantee.

Please forward the serial number of the equipment in

the event of any guarantee claim.

Return of the equipment requires our prior consent.

Transportation and related costs will be at the expen-
se of the purchaser (please refer to the General Sales
Conditions).

Copyright
Copyright to this instruction manual remains the pro-
perty of Castolin.
Text and illustrations are all technically correct at the
time of going to print. Right to effect modications
is reserved. The contents of the instruction manual
shall not provide the basis for any claims whatever on
the part of the purchaser. If you have any suggestions
for improvement, or can point out to us any mistakes
which you may have found in the manual, we should
be most grateful.

General remarks

Principle of the Derby 425 DS

This welding machine is a MIG/MAG gas-shielded unit
with optimum welding properties. Its area of applica-
tion ranges from sheet-metal working all the way up
to light structural steel work and portal construction.
Its ability to weld ux-cored wires ofvarious different
diameters and alloys under various commonly avai-
lable shielding gases extends its area of use to take in
the production and repair elds. It goes without saying
that thismachine comes with preselectable control
routines such as 2-step, 4-step.

Machine concept - Derby 425 DS

The Derby 425 DS was designed as a two-part unit
and is built to function dependably under even the
toughest operating conditions. Features such as its
powder-coated sheet-steelhousing, protected controls
and torch central connector all testify to the high quali-
ty of its design. Thanks to its insulated carrying handle
and large-wheeled trolley, the machine is easy to move
around. The portable wirefeeder unit can either be
placed on top ofthe power source or mounted on an in-
termediate trolley so asto extend the operating range.
Front and back panel description 25. Burn-back time correction dial
1. ON/OFF switch Where correctly adjusted, this prevents the wel-
2. 4 position switch - coarse regulation ding wire freezing to the weld puddle or the con-
3. 6 position switch - ne regulation tact tube
4. Pilot Lamp indicating power is applied to the unit 26. Soft-start speed dial
5. Pilot Lamp indicating the intervention of the ther- For setting a jerk-free ignition cycle when working
mostatic protection with solid and ux-cored wires from diam. 1.2mm
6. Regulation of the wire speed upwards and/or at high wire feed speeds
7. Manual (2 time) /automatic (4 time) Selector : 27. Max. wire feed speed switch
Manual: keep the torch trigger pressed to weld; 11 m/min allows a more ne adjustment of the
Automatic: press and release the torch trigger to wire feed speed
start welding, press and release it again to stop.
8. Euro torch connector Operating modes
9. Input Cable
10. Negative connection for thin thicknesses (low reac- 2-step mode
tance) - Gas welding 2-step operation is often used for tacking-jobs, short
11. Negative connection for thick thicknesses (high re- weld-seams and in automatic welding.
actance) - Gas welding
12. Voltmeter/Ammeter (optional)
13. 6 poles connector for the interconnection cable
14. Positive connectors for the interconnection cable
for gas welding and for the earth cable for no gas
welding.
15. Gas connector for the interconnection cable.
16. 230V connector for the water cooler. Max power
400VA. Do not connect anything else.
17. Pilot Lamp indicating power is appied to the water
cooler.
18. Pilot Lam,p indicating lack of refrigerant.
19. Fuse
20. Safety device connection cable (manostat) of the
water cooler.
21. Input cable of separate wire feeder (it must be con-
nected to the 230V connection -16-) 4-step mode
22. Quick connectors for the hoses marked with the adhe- 4-step mode is particularly suitable for longer weld
sive red and blu ring of the interconnection cable. seams.
23. Quick connectors for the hoses marked with the ad-
hesive red and blu ring of the torch.
24. Negative connection (low reactance)- No gas weld-
ing.

Wire feeder inside description

Starting to use the welding machine
Warning! Before starting to use for the rst
time, read thesection headed Safety rules.
Utilisation for intended purpose only
The welding machine is intended to be used SOLELY for
MIG/MAG welding.
Any other use, or any use going beyond the above, is
deemed to be not for the intended purpose and the
manufacturer shall not be liable for any damage resul-
ting there from.
Utilisation for the intended purpose shall also be dee-
med toencompass:
the observance of all instructions in the operating
manual
the carrying out of all prescribed inspection and
maintenance work
Warning! Never use the welding machine for
thawingfrozen pipes.
Machine set-up regulations
The welding machine is tested to Degree of protection
IP22, meaning:
Protection against penetration by solid foreign
bodies withdiameters larger than 12 mm
Protecion against the fall of water droplets at 15
angle of the unit vertical
The welding machine has been set up for indoor opera-
tion inaccordance with IP 22. If appropriate measures
are taken toguard against direct wetting, the machine
can also be used limitedly outdoors.
Warning! Place the welding machine on an
even, rmoor in such a way that it stands
rmly. A welding machine that topples over can
easily kill someone.
The venting duct is a very important safety feature.
When choosing the machine location, make sure that
it is possible forthe cooling air to enter and exit unhin-
dered through the louverson the front and back of the
machine. Any metallic dust from e.g. grinding-work
must not be allowed to get sucked into themachine.
Warning! Applies to designs with gas bottle hol-
der, where the unit gas bottle holder/rear axle is
not preas-sembled.
Secure the rear axle against twisting using
a bolt pinin the centre of the axle.
Mains connection
The welding machine is designed to run on the mains
voltage given on the rating plate. For details of fuse
protection of the mains supply lead, please see the
Technical Data.
Derby 425 can be run on a mains voltage of either
3x230/400V~.
The Derby 425 DS power sources are factory-connected
for 400 V. This means that thanks to its +/-10% toleran-
ce range, the power source can also be run on the 380
V~ or 415 V~ mains.
Warning! If the machine is designed to run on
a specialvoltage, the Technical Data shown on
the rating plateapply. The mains plug and mains
supply lead, and theirfuse protection, must be
dimensioned accordingly.
Unit assembly
Assembly of the unit should be carried out by trained
personnel in compliance with current standards and
abide by all safety regulations.
1. Unpack the unit.
2. Fit the two front castor wheels (1).
3. Fix the axle support (2) to the lower panel of the
power source using the supplied screws.
4. Fit the axle ( 3) of the back wheels (4) into the holes
and x the wheels (4) using the supplied rings (5).
5. Install the wire feeder handle (6) on the top panel
and x it using the supplied scews (F).
6. Fit the four castor wheels (7) to the rear panel of the
wire feeder.
7. Install the black pivoting base (8) on the top panel of
the power source using the supplied screws.
Assembly of the unit with the water cooler
1. Remove the top panel of the power source by remo-
ving the screws.
2. Thread the connection cable of the safety device
(manostat) (20) into the cable clamp (25) on the
left of the back panel.
3. Remove the CN2 bridge to allow the connection of
the safety device to the terminal box.
4. Tighten the cable clamp.
5. Mount the top panel.
6. Install the support (9) on the top panel of the po-
wer source using the supplied screws.
7. Install the water cooler to the support.
8. Fit the plug of the water cooler into the connection
(16) on the back panel of the power source.
9. Connect the interconnection cable hoses to the
quick connectors (22) on the back panel of the wire
feeder.
10. Install the torch on the front panel of the wire fee-
der and tighten through the nut.
11. Connect the torch hoses to the quick connectors
(23) on the front panel of the wire feeder.
12. Fill the tank.
13. Install the black pivoting base (8) on the water coo-
ler top using the supplied screws.
14. Place the wire feeder.
Torch connection Gas cylinder installation
Connect the gas hose to the torch connection (the unit Fix the gas cylinder to the holder using the supplied
is not supplied with the torch) . chain.
The torch is the part of the equipment that needs most Screw the regulator into the cylindervalve and tighten
maintenance. We recommend to check periodically the with a wrench (excessive tightening could cause
contact tips and the nozzle, these parts must be clean and damages to the cylinder and to the regulator).
not worn-out. The torch liner must be replaced when the Firmly push the gas hose over barbed ttings on back
wire does not run smoothly. of wire feeder securing it with a hose clamp
Open the gas on the regulator, press the torch
Loading of the welding wire trigger and check gas is flowing out of the torch.
Warning! No wire spool is supplied with the
unit. Material to weld Gas Wire
Mild steel Argon + CO2 Coppered steel, for welding wit-
or CO2 hout gas ux cored wire
To load welding wire into the feeding system follow the
Stainless steel Argon Stainless steel wire
following instructions (2).
Aluminium Argon Aluminium wire
1. Ensure the gas and electrical supplies are discon-
nected. Before proceeding, remove the nozzle and
the contact tip from the torch.
2. Open the side panel.
3. Unscrew the nut on the spool holder.
4. Remove the empty spool.
5. Remove the plastic protection from the new spool.
6. Install the new spool on the spool holder.
7. Replace the nut.
8. Loose and lower the plastic knob, release the upper
rolls of the feeder and extract the remaining wire
from the torch liner.
9. When the wire is disconnected, grasp it with pliers
so that it cannot exit from the spool. If necessary,
straighten it before inserting it in the wire input
guide . Insert the wire on the lower rolls and in the
torch liner. WARNING: Keep the torch straight. Cut
away the rst 10cm of wire making sure it is cut
cleanly (no burrs or angles). Failure to follow these
instructions could cause damage to the liner.
10. Lower the upper roll (B) and place the knob (A).
Tighten slightly. If tightened too much, the wire
gets locked and could cause motor damage. Ifnot
tighten enough, the rolls will not feed the wire.
NOTE: rolls have two grooves of different size. If you
intend to weld without gas, reverse the rolls posi-
tion adapting the right grooves to the diameter of
the ux cored wire you are using.
MIG/MAG welding with gas MIG/MAG welding without gas

Caution!
Before starting up for the rst time, read the sections Schweien ohne Gas:
headed Safety rules and Starting to use the power
source.

Connect the earth cable plug to the positive socket

Connect the earth cable plug to the negetive socket
on the power source (choose between low and high
reactance ) placed on the bottom right side of the
front panel.
Connect the earth clamp to the workpiece.
Connect the torch cable to the positive poles of the
unit.
Plug the machine into the mains
Shift the mains switch to the I position
Set the welding voltage with step switch , and the
wirefeed speed with the wirefeed-speed dial
Shift the operating mode selector switch into the
requiredposition
Open the gas-cylinder valve
Set the gas ow-rate
Press the torch trigger and start welding
of the power source placed on the left side of the
back panel.
Connect the earth clamp to the workpiece.
Connect the torch cable to the positive pole of the
wire feeder and to the negative pole of the power
source.
Plug the machine into the mains
Shift the mains switch to the I position
Set the welding voltage with step switch , and the
wirefeed speed with the wirefeed-speed dial
Set the welding voltage with step switch , and the
wirefeed speed with the wirefeed-speed dial
Shift the operating mode selector switch into the
requiredposition
Press the torch trigger and start welding

Setting the operating point

One of the basic preconditions for obtaining an opti-
mum welding result with the MIG/MAG welding pro-
cess is that the operating point has been determined
correctly. This is basically effected by selecting mutually
compatible welding voltages(step switch ) and wire-
feed speeds (wirefeed-speed dial ).
Fine adjustments can be done with the setting of the
wire burnback time and the soft start.
Care and maintenance

Warning! Before opening up the welding machi-

ne, switch it off, unplug it from the mains and
put up a warning sign to stop anybody inadver-
tently switching it back on again.If necessary,
discharge the electrolytic capacitors.

In order to keep your welding machine operational

for years to come, you should observe the following
points:
Carry out safety inspections at the stipulated inter-
vals (see the section headed Safety rules)
Depending on the machine location, but no less of-
ten than twice a year, remove the side panels from
the machine and blow the inside of the machine
clean with dry, reduced-blowcompressed air. Do not
aim air-jets at electronic componentsfrom too close
a range.
If a lot of dust has accumulated, clean the cooling-
air ducts.
Technical Data

Warning! If the machine is designed to run on a special voltage, the Technical Data shown on the rating
plate apply. The mains plug and mains supply lead, and their fuse protection, must be dimensioned accor-
dingly.

Derby 425 DS
Mains voltage +/-10% 3 x 230 / 400 V
Mains fuse protection 230 V 40 A slow
400 V 25 A slow
Cos phi 150 A 0,90
Primary continous power
35% Duty cycle 19 kVA
60% Duty cycle 13 kVA
100% Duty cycle 9 kVA
Welding current range 30 - 400 A
Welding current at
35% Duty cycle 400 A
60% Duty cycle 305 A
100% Duty cycle 236 A
Open-circuit voltage 18 - 47 V
Working voltage 15,5 - 34 V
Number of switching steps 6x4
Inductance taps 2
Degree of protection IP 22
Type of cooling AF
Insulation class H
Quality marks S, CE