Related Manuals for BOC Smootharc Elite MMA 162 VRD
Summary of Contents for BOC Smootharc Elite MMA 162 VRD
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Page 1: Operating Instructions
Operating instructions Welding machine Smootharc Elite MMA 162 VRD 099-002050-BOC01 30.11.2009... -
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
3.2.3 Welding in environments with increased electrical hazards .........13 3.2.4 Service documents (spare parts and circuit diagrams) ..........13 4 Machine description – quick overview....................14 Smootharc Elite MMA 162 VRD....................14 4.1.1 Front view ........................14 4.1.2 Rear view........................15 Machine control – Operating elements ..................16 5 Design and function..........................17... - Page 5 Contents Notes on the use of these operating instructions 6 Maintenance, care and disposal......................26 General ............................26 Maintenance work, intervals ......................26 6.2.1 Daily maintenance tasks ....................26 6.2.2 Monthly maintenance tasks..................26 6.2.3 Annual test (inspection and testing during operation) ..........26 Repair Work ..........................
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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 Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - 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: 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 13: 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 14: Machine Description - Quick Overview
Machine description – quick overview Smootharc Elite MMA 162 VRD Machine description – quick overview Smootharc Elite MMA 162 VRD 4.1.1 Front view Figure 4-1 Item Symbol Description Carrying strap Machine control See Machine control – operating elements chapter Connection socket, "+" welding current •... -
Page 15: Rear View
Machine description – quick overview Smootharc Elite MMA 162 VRD 4.1.2 Rear view Figure 4-2 Item Symbol Description Mains connection cable Main switch, machine on/off Cooling air inlet 099-002050-BOC01 30.11.2009... -
Page 16: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Welding process changeover switch • = MMA welding • = TIG welding Welding current rotary dial Infinite adjustment of the welding current from 10A to maximum current Ready for operation signal light Signal light on when the machine is switched on and ready for operation VRD open circuit voltage reduction... -
Page 17: Design And Function
Design and function General Design and function 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. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 18: 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 19: 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 20: Mma Welding
Design and function MMA welding 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 21: Selecting Mma Welding
Design and function MMA welding 5.6.2 Selecting MMA welding Operating Action Result element welding process selected Main current setting 5.6.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular. -
Page 22: Tig Welding
Design and function TIG welding TIG welding NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-4 Item Symbol Description Connection socket, “+” welding current Connection for workpiece lead “-” Welding current connection socket TIG welding torch welding current lead connection 5.7.1.1 Connecting a TIG welding torch with rotating gas valve... -
Page 23: Shielding Gas Supply
Design and function TIG welding 5.7.1.3 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 24: 5.7.3 Tig Arc Ignition
Design and function Voltage reducing device 5.7.3 TIG arc ignition Figure 5-5 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece (liftarc current flowing, regardless of the main current set). b) Incline the torch towards the torch gas nozzle until there is a gap of approx. -
Page 25: Dirt Filter
Design and function Dirt filter Dirt filter NOTE These accessory components can be retrofitted as an option, see Accessories chapter. The dirt filter can be used in places with unusually high levels of dirt and dust in the ambient air. The filter reduces the duty cycle of the welding machine via the reduced flow of cooling air. -
Page 26: 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 27: 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 28: Rectifying Faults
Rectifying faults Machine faults (error messages) 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 29: Technical Data
Technical data Smootharc Elite MMA 162 Technical data Smootharc Elite MMA 162 Setting range Welding current 10 A to 150 A 10 A to 160 A Setting range Welding voltage 20.4 V to 26.0 V 10.4 V to 16.4 V Duty cycle at 25 °C 160 A 45 %... -
Page 30: Accessories, Options
Accessories, options General accessories Accessories, options General accessories Type Description / Name ADAP 16/25-35 QMM Welding current socket adapter from 16/25 to 30 QMM ON FILTER Retrofit option, dirt filter for air inlet 099-002050-BOC01 30.11.2009...
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