Related Manuals for BOC Smootharc Elite MIG 451 Progress Pulse
Summary of Contents for BOC Smootharc Elite MIG 451 Progress Pulse
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Page 1: Operating Instructions
Operating instructions Welding machine Smootharc Elite MIG 451 Progress Pulse Observe additional system documents! 099-004839-BOC01 10.11.2009... -
Page 2: General Instructions
+61 (02) 8874 4721. A list of authorised sales partners can be found at www.boc.com.au or www.boc.co.nz Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. - Page 3 Premium quality with a three-year warranty - Five year warranty on transformers and rectifiers Congratulations on purchasing a BOC SMOOTHARC ELITE machine. You have chosen a quality product from EWM Hightec Welding – Germany’s leading manufacturer and technology expert of arc welding machines.
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Page 4: Table Of Contents
3.3.3 Welding in environments with increased electrical hazards .........15 3.3.4 Service documents (spare parts and circuit diagrams) ..........15 4 Machine description – quick overview....................16 Smootharc Elite MIG 451 Progress Pulse ...................16 4.1.1 Front view ........................16 4.1.2 Rear view........................18 5 Design and function..........................20 General............................20... - Page 5 Resetting all JOBs ......................37 General operating problems ......................38 7.4.1 Interface for mechanised welding.................38 8 Technical data ............................39 Smootharc Elite MIG 451 Progress Pulse ...................39 9 Accessories, options ........................... 40 System components ........................40 General accessories ........................40 Welding torch ..........................40 9.3.1...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... - Page 7 Safety instructions Notes on the use of these operating instructions Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press...
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Page 8: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 9 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 10 Please note that under no circumstances should any equipment or parts be altered or changed in any way from the standard specification without written permission given by BOC. To do so, will void the Equipment Warranty. • Further information can be obtained from Welding Institute of Australia (WTIA) Technical Note No.7 ´Health and Safety Welding` Published by WTIA, PO Box 6165 Silverwater NSW...
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Lifting By Crane
Safety instructions Transport and installation 2.3.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig. -
Page 13: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 14: Intended Use
Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. -
Page 15: Use And Operation Solely With The Following Machines
Intended use Use and operation solely with the following machines Use and operation solely with the following machines NOTE A suitable wire feed unit (system component) is required in order to operate the welding machine! Smootharc Elite MIG 451 PROGRESS Elite Wire Feeder PP 451 Documents which also apply 3.3.1... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Smootharc Elite MIG 451 Progress Pulse Machine description – quick overview Smootharc Elite MIG 451 Progress Pulse 4.1.1 Front view Figure 4-1 099-004839-BOC01 10.11.2009... - Page 17 Machine description – quick overview Smootharc Elite MIG 451 Progress Pulse Item Symbol Description Lifting lug Signal light, Ready Main switch, machine on/off Carrying handle Connection socket, “+” welding current Connection socket, “-” welding current Coolant tank cap Coolant tank...
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Page 18: Rear View
Machine description – quick overview Smootharc Elite MIG 451 Progress Pulse 4.1.2 Rear view NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Figure 4-2 099-004839-BOC01 10.11.2009... - Page 19 Machine description – quick overview Smootharc Elite MIG 451 Progress Pulse Item Symbol Description Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 19-pole mechanised welding interface (analogue) (See chapter entitled "Design and function > interfaces".)
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Page 20: Design And Function
Design and function General Design and function NOTE Observe documentation of other system components when connecting! General DANGER Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. •... -
Page 21: Installation
Design and function Installation Installation CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 22: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.5.1 General CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •... -
Page 23: Adding Coolant
Design and function Welding torch cooling system 5.5.3 Adding coolant NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary. -
Page 24: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)! -
Page 25: Interconnecting Cable Connection
Design and function Interconnecting cable connection Interconnecting cable connection NOTE Note the polarity of the welding current! Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 26: Mig/Mag Welding
Design and function MIG/MAG welding • Insert the end of the tube package through the strain relief of the tube package and lock by turning to the right. • Insert the plug on the welding current lead into the welding current connection socket "+" and lock. •... -
Page 27: Tig Welding
Design and function TIG welding TIG welding 5.9.1 Welding torch connection NOTE TIG combi welding torches are connected to wire feed unit and power source. The welding current for the intermediate hose package must be connected to the welding current connection (-) at the rear of the unit! Connection example: wire feed unit alpha Q Drive 4L. -
Page 28: Connection For Workpiece Lead
Design and function TIG welding 5.9.2 Connection for workpiece lead Figure 5-6 Item Symbol Description Connection socket, "+" welding current • TIG welding: Workpiece connection • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right. -
Page 29: Mma Welding
Design and function MMA welding 5.10 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 30: Interfaces
Design and function Interfaces 5.11 Interfaces CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 31: Rint X11 Robot Interface
Design and function Interfaces 5.11.2 RINT X11 robot interface The standard digital interface for automated applications (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: Start/stop, operating mode, job and program selection, inching, gas test •... -
Page 32: Shielding Gas Supply
Design and function Shielding gas supply 5.12 Shielding gas supply 5.12.1 Connecting the shielding gas supply WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 33: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 34: Repair Work
Maintenance, care and disposal Repair Work Repair Work DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •... -
Page 35: Rectifying Faults
Rectifying faults Customer checklist Rectifying faults All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer. -
Page 36: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer. -
Page 37: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. 7.3.1 Resetting a single JOB JOB- JOB- LIST LIST m/min... -
Page 38: General Operating Problems
Rectifying faults General operating problems General operating problems Problem Possible cause > remedy Machine control without displaying the signal • Phase failure > check mains connection (fuses) lights after switching on no welding performance • Phase failure > check mains connection (fuses) various parameters cannot be set •... -
Page 39: Technical Data
Technical data Smootharc Elite MIG 451 Progress Pulse Technical data Smootharc Elite MIG 451 Progress Pulse NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Adjusting range Welding current/voltage: 5 A / 10,2 V bis 450 A / 28 V... -
Page 40: Accessories, Options
Accessories, options System components Accessories, options System components Elite Wire feeder PP 451 MIG/MAG wire feed unit 090-004844-00032 General accessories Type Designation Item no. AK300 Adapter for K300 basket coil 094-001803-00001 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-00000 KF 23E-200 Coolant (-10°C), 200 litres... -
Page 41: Options
Accessories, options Options Options Type Designation Item no. ON FSB WHEELS W/T/P Retrofit option for locking brake for machine wheels 092-002110-00000 ON TRAVERSE DRIVE 4L Retrofit option for TETRIX/PHOENIX DRIVE 4 L 092-002112-00000 star handle ON TRAVERSE PHOENIX Retrofit option star handle PHOENIX DRIVE 4 092-002280-00000 DRIVE 4 ON HOSE/FR MOUNT DK...
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