+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.
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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.
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................4 2 Safety instructions ..........................6 Notes on the use of these operating instructions................6 General............................8 Transport and installation......................11 Ambient conditions........................12 2.4.1 In operation........................12 2.4.2 Transport and storage ....................12 3 Intended use ............................13 Applications..........................13 Documents which also apply......................13 3.2.1...
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Contents Notes on the use of these operating instructions 5.8.6 Pulse variants .......................38 5.8.6.1 Pulses (thermal pulses) ................38 5.8.6.2 Automated pulses ..................39 5.8.6.3 AC pulses...................... 39 5.8.6.4 AC special ..................... 39 5.8.7 TIG activArc welding..................... 40 5.8.8 Welding torch (operating variants) ................41 5.8.9 Torch mode and up/down speed setting ..............
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. •...
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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...
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. •...
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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! •...
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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...
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! •...
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.
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.
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements T 2.30 Puls Automatic VOLT special DC + DC - AMP% AMP% AMP% 4> 4> JOB 0 Figure 4-3 Item Symbol Description Welding process button MMA welding TIG welding Operating mode button...
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Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding current polarity button Direct current welding with positive polarity on the electrode holder in relation to the workpiece (pole reversal switch, MMA only). DC welding with negative polarity on the torch (or stick electrode holder) in relation to the workpiece.
Machine description – quick overview Machine control – Operating elements 4.2.1 Function sequence AMP% AMP% AMP% Figure 4-4 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Gas pre-flow time (TIG) Absolute setting range 0.1 s to 5.0 s (0.1 s increments).
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Machine description – quick overview Machine control – Operating elements Item Symbol Description Tungsten electrode diameter / Ignition optimisation (TIG) Infinitely adjustable from 1 mm to 4 mm or greater (0,1 mm increments) Alternating current balance (TIG AC) Max. setting range: -30 % to +30 % (1% increments). Optimisation of cleaning effect and fusion penetration characteristics.
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! •...
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.
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)!
Design and function TIG welding TIG welding 5.6.1 Connecting the welding torch and workpiece lead NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-2 Item Symbol Description Connection socket, "-" welding current Welding current lead connection for TIG welding torch G¼"...
Design and function TIG welding 5.6.2 Torch connection options and pin assignments Down Uref 10V Uref 10V IH-Down Poti UD/ein Poti UD/ein 5-pole control lead 8-pole control lead 12-pole control lead Figure 5-3 5.6.3 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
Design and function TIG welding 5.6.3.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-4 Item Symbol Description Pressure reducer Shielding gas cylinder Output side of the pressure reducer Cylinder valve •...
Design and function TIG welding 5.6.3.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.
Design and function Select welding task Select welding task Operating Action Result element Select and display welding process MMA welding TIG welding Select and display welding current polarity Direct current welding with positive polarity at the electrode holder (MMA). DC welding with negative polarity at the torch (or electrode holder) with respect to the workpiece.
Design and function Select welding task 5.7.1 Save welding tasks (JOBs) All user settings are saved immediately after being modified or changed. No special save command or user input is needed. The last welding parameters that were used are available even after switching off and on again. There are altogether 8 JOBs that can be used to save the respective parameters for different frequently occurring welding tasks.
Design and function Select welding task 5.7.2 Welding data display The following welding parameters can be displayed before (nominal values) or during (actual values) welding. Parameter Before welding During welding (nominal values) (actual values) Welding current Welding voltage JOB number Parameter times Frequency, balance Parameter currents...
Design and function TIG welding TIG welding 5.8.1 Arc ignition 5.8.1.1 HF ignition Figure 5-6 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx.
Design and function TIG welding 5.8.2 Optimising the ignition characteristics for pure tungsten electrodes The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used. The set value should correspond to the diameter of the tungsten electrode.
Design and function TIG welding 5.8.4 Function sequences/operating modes The parameters for the function sequence are set using the “Select welding parameters” button and the “Welding parameter setting” rotary dial. Pos. Description T 2.30 Puls “Select welding parameters” button Automatic VOLT “Welding parameter setting”...
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Design and function TIG welding Non-latched mode NOTE When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off. AMP% start Down Figure 5-9 1st cycle: • Press and hold torch trigger 1. •...
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Design and function TIG welding Latched mode NOTE When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off. AMP% start Down Figure 5-10 Step 1 • Press torch trigger 1, the gas pre-flow time elapses. •...
Design and function TIG welding 5.8.4.2 SpotArc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. NOTE The up-slope and down-slope times should be set to “0 s”...
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Design and function TIG welding Sequence: • Press and hold torch trigger 1. • The gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. • The welding current flows and immediately assumes the value set for the ignition current I start •...
Design and function TIG welding 5.8.5 Pulses, function sequences NOTE The function sequences in pulses basically behave in the same way as in standard welding, but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times. 5.8.5.1 TIG pulses –...
Design and function TIG welding 5.8.6 Pulse variants NOTE The machines have an integrated pulse device. With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current). 5.8.6.1 Pulses (thermal pulses) AMP% Figure 5-14 Operating Action...
Design and function TIG welding 5.8.6.2 Automated pulses The automated pulses are used with tacking and spot welding of workpieces in particular. An oscillation in the molten pool is produced by the current-dependent pulse frequency and balance, which positively influences the ability to bridge the air gap. The pulse parameters required are automatically specified by the machine control.
Design and function TIG welding 5.8.7 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g.
Design and function TIG welding 5.8.8 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger...
Design and function TIG welding 5.8.9 Torch mode and up/down speed setting The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function options as 1 to 4, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types.
Design and function TIG welding 5.8.9.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements BRT 1 Welding current On/Off (factory-set) BRT 1...
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Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements BRT 1 Welding current On/Off Secondary current BRT 2 (factory-set)
Design and function TIG welding 5.8.9.3 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode...
Design and function TIG welding 5.8.9.4 RETOX TIG torch (12-pole) NOTE For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)! Diagram Operating elements Explanation of symbols TT= torch trigger BRT 1 BRT 3...
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 •...
Design and function MMA welding 5.9.2 Select welding task Operating Action Result element Select MMA welding process signal light lights up in green Set welding current 5.9.3 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current...
Design and function Remote control 5.10 Remote control NOTE The remote control is operated on the 19-pole remote control connection socket. • If required, extension cables are available in different lengths (see chapter Accessories). • Plug the remote control unit into the remote control connection socket on the welding machine or wire feed unit and lock it only when the machine is switched off.
Design and function Interfaces for automation 5.11 Interfaces for automation 5.11.1 Remote control connection socket, 19-pole CAUTION Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. •...
Design and function Advanced settings 5.12 Advanced settings 5.12.1 Testing the machine fan The machine fan can be switched on at the machine controls so that you can check that it is working correctly. VOLT Figure 5-19 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings...
Design and function Advanced settings 5.12.2 Limiting the mains current (10A) If the plug socket has a 10A mains fuse in order to comply with national regulations, it may be necessary to reduce the mains current of the welding machine to 10A in order to avoid triggering the fuse. This restricts the welding machine's power input.
Design and function Advanced settings 5.12.3 Protecting welding parameters from unauthorised access To protect against unauthorised or unintentional changes to the welding parameters, you can lock the machine controls with a software key (3-digit machine code). If the access lock is active, only the following parameters can be changed: •...
Design and function Advanced settings 5.12.3.1 Changing the three-digit machine code In this menu you can change the 3-digit machine code. After entering and confirming the old code, you can enter a new code. The correct machine code is necessary for activating and deactivating the access lock! VOLT Figure 5-22 Display...
Design and function Advanced settings 5.12.4 Setting the welding current (absolute/percentage) The welding currents for start current, secondary current, end current and hotstart current can be set as percentages (factory setting) or absolute values. If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the respective "AMP%"...
Design and function Advanced settings 5.12.5 Selecting the welding current polarity during the ignition phase Selection of welding current polarity during ignition phase, until the arc stabilises. It always switches over to DC- polarity after a few milliseconds. VOLT Figure 5-24 Display Setting/selection Lock JOB menu...
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! •...
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. •...
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.
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. VOLT Figure 7-1 Display Setting/selection Input confirmation User entries are applied, release button(s). 099-000143-BOC01 16.11.2009...
Rectifying faults Resetting welding parameters to the factory settings 7.2.1 Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! VOLT Figure 7-2 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings Exit the menu...
Technical data Smootharc TIG 230 AC/DC Technical data Smootharc TIG 230 AC/DC NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Setting range Welding current 3 A-230 A 5 A-180 A 5 A-230 A 5 A-180 A Welding voltage 10.1V-19.2V 20.2V-27.2V...
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