BOC Smootharc Elite MIG 451 Progress Pulse, Operating Instructions Manual

Page 1: ...Operating instructions Welding machine Smootharc Elite MIG 451 Progress Pulse Observe additional system documents 099 004839 BOC01 10 11 2009 ...

Page 2: ...solely to the function of the equipment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly p...

Page 3: ...the operating instructions In all their high tech components these welding machines embody future oriented advanced technology at the utmost level of quality Each of these products is carefully checked EWM guarantee that the material and processing of these products is faultless These operating instructions contain everything about commissioning the machine notes regarding safety maintenance and c...

Page 4: ...uick overview 16 4 1 Smootharc Elite MIG 451 Progress Pulse 16 4 1 1 Front view 16 4 1 2 Rear view 18 5 Design and function 20 5 1 General 20 5 2 Installation 21 5 3 Machine cooling 21 5 4 Workpiece lead general 21 5 5 Welding torch cooling system 22 5 5 1 General 22 5 5 2 List of coolants 22 5 5 3 Adding coolant 23 5 6 Mains connection 24 5 6 1 Mains configuration 24 5 7 Interconnecting cable con...

Page 5: ...ist 35 7 2 Error messages power source 36 7 3 Resetting JOBs welding tasks to the factory settings 37 7 3 1 Resetting a single JOB 37 7 3 2 Resetting all JOBs 37 7 4 General operating problems 38 7 4 1 Interface for mechanised welding 38 8 Technical data 39 8 1 Smootharc Elite MIG 451 Progress Pulse 39 9 Accessories options 40 9 1 System components 40 9 2 General accessories 40 9 3 Welding torch 4...

Page 6: ...al warning symbol The hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which...

Page 7: ...et points e g Insert the welding current lead socket into the relevant socket and lock Symbol Description Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required us...

Page 8: ... may be affected obtain advice from a doctor if necessary 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 Appoint only skilled persons for repair work trained service personnel WARNING Risk of accidents...

Page 9: ...hot slag produced during the welding process Stray welding currents can also result in flames forming Check for fire hazards in the working area Do not carry any easily flammable objects such as matches or lighters Keep appropriate fire extinguishing equipment to hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue ...

Page 10: ...lia WTIA Technical Note No 7 Health and Safety Welding Published by WTIA PO Box 6165 Silverwater NSW 2128 Phone 02 9748 4443 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 pr...

Page 11: ...e tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 3 10 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Damage due to supply lines not being disconnected During transport supply lines which have not been disconnected mains supply leads ...

Page 12: ...g e g shielding gas cylinders tool boxes wire feed units etc Avoid jerky movements when raising or lowering Use shackles and load hooks of the appropriate size m i n 1 m 75 Fig Lifting principle Risk of injury due to unsuitable ring screws In case of improper use of ring screws or the use of unsuitable ring screws persons can be seriously damaged by falling equipment or add on components The ring ...

Page 13: ...es of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distance ...

Page 14: ... MAG standard welding Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the molten pool to protect them from the atmosphere 3 1 2 forceArc Welding with a powerful forced arc deep fusion penetration and virtually spatter free weld seams of the highest quality 3 1 3 MIG MAG pulse welding Welding process for optimum welding results when joining stainle...

Page 15: ...ised modifications improperly conducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 3 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used ...

Page 16: ...on quick overview Smootharc Elite MIG 451 Progress Pulse 16 099 004839 BOC01 10 11 2009 4 Machine description quick overview 4 1 Smootharc Elite MIG 451 Progress Pulse 4 1 1 Front view 6 7 4 3 2 1 10 5 9 11 8 Figure 4 1 ...

Page 17: ...tion 0 1 Lifting lug 2 Signal light Ready 3 Main switch machine on off 4 Carrying handle 5 Connection socket welding current 6 Connection socket welding current 7 Coolant tank cap 8 Coolant tank 9 Automatic cut out of coolant pump key button press to reset a triggered fuse 10 Cooling air inlet 11 Conveyor rolls guide castors ...

Page 18: ...s Pulse 18 099 004839 BOC01 10 11 2009 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 6 7 4 3 2 1 10 5 9 14 11 8 12 13 Figure 4 2 ...

Page 19: ...onnecting digital accessory components documentation interface robot interface or remote control etc 5 COM PC interface serial D SUB connection socket 9 pole 6 Connection socket welding current Welding current to WF central connection torch 7 Connection socket welding current Welding current to WF central connection torch 8 Coolant return from the DV device red rapid action closure coupling 9 Cool...

Page 20: ...ot reach into rotating or moving parts or drive components Keep casing covers closed during operation Risk of injury due to welding wire escaping in an unpredictable manner Welding wire can be conveyed at very high speeds and if conveyed incorrectly may escape in an uncontrolled manner and injure persons Before mains connection set up the complete wire guide system from the wire spool to the weldi...

Page 21: ...omponents the following precautions should be observed Ensure that the working area is adequately ventilated Do not obstruct the air inlets and outlets of the machine Do not allow metal parts dust or other objects to get into the machine 5 4 Workpiece lead general CAUTION Risk of burns due to incorrect connection of the workpiece lead Paint rust and dirt on the connection restrict the power flow a...

Page 22: ...ust be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester see accessories Replace coolant as necessary if frost protection is inadequate NOTE The disposal of coolant must be carried out according to official regulations and obs...

Page 23: ...filling process the cooling unit tank should be topped up as necessary The unit is supplied ex works with a minimum level of coolant 4 3 2 1 Figure 5 1 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Min mark Minimum coolant level 4 Coolant tank Unscrew and remove the coolant tank sealing cover Check filter sieve insert for dirt clean if necessary and reinsert into position T...

Page 24: ...ains plug socket and lead must be checked regularly by an electrician 5 6 1 Mains configuration NOTE The machine may be connected to TN TT or IT networks with a protective conductor as available L1 L3 L2 PE Figure 5 2 Legend Item Designation Colour code L1 Outer conductor 1 black L2 Outer conductor 2 brown L3 Outer conductor 3 grey PE Protective conductor green yellow CAUTION Operating voltage mai...

Page 25: ...the welding current socket Observe the information from the electrode manufacturer 6 7 8 4 3 2 5 1 Figure 5 3 Item Symbol Description 0 1 Wire feed unit 2 Intermediate tube package 3 Intermediate tube package strain relief 4 7 pole connection socket digital Wire feed unit connection Connection socket welding current 5 MIG MAG welding Welding current to central connection torch welding current conn...

Page 26: ... closure coupling red coolant return and supply line blue to rapid action closure coupling blue coolant supply 5 8 MIG MAG welding 5 8 1 Connection for workpiece lead 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 workp...

Page 27: ...gas and torch trigger 2 Rapid action closure coupling red coolant return 3 Rapid action closure coupling blue coolant supply welding current connection socket 4 TIG welding Welding current connection for welding torch Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the welding current plug on the combi torch into the welding current...

Page 28: ...5 9 2 Connection for workpiece lead 1 Figure 5 6 Item Symbol Description 0 Connection socket welding current 1 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: ... on an insulated surface 5 10 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging 1 2 Figure 5 7 Item Symbol Description 0 1 Connection socket welding current 2 Connection socket welding current Insert cable plug of the electrode holder into either the or welding current connection socket an...

Page 30: ...rce is switched on 5 11 1 Automation interface NOTE These accessory components can be retrofitted as an option see Accessories chapter Pin Input output Description Diagram A Output PE Connection for cable shielding D Output open collector IGRO Current flows signal I 0 maximum load 20 mA 15 V 0 V welding current flows E R Input Not Aus Emergency stop for higher level shut down of the power source T...

Page 31: ... the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be connected between the PC and the welding machine The connection must only be made using the cables supplied do not use any additional extension cables PC 300 welding parameter software Create all welding parameters q...

Page 32: ...rs provided for them and secure with fixing devices Avoid heating the shielding gas cylinder DANGER Risk of injury caused by shielding gas cylinders toppling over Shielding gas cylinders may topple over and cause serious injury if not adequately secured Secure shielding gas cylinders with the securing device chain strap supplied as standard with the machine Securing devices must fit tightly around...

Page 33: ... valve Gas cylinder securing elements Operating message safety and adjustment devices Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls Transport rollers and their securing elements Transport elements strap lifting lugs handle Selector switches command devices emergency stop devices voltage reducing devices message and control lamps Check coolant tubes...

Page 34: ...horised personnel otherwise the right to claim under warranty is void In all service matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as wel...

Page 35: ...rrectly Wire feed irregular Contact nozzle too small Check replace if necessary Incorrect shielding gas setting Correct Rule of thumb Wire diameter 10 flow in l min Gas cylinder empty Change Electrode is projecting too far forwards Move torch closer to weld seam Air current Shield welding area Poor wire quality Use high quality wire store in a dry and clean location Very dirty workpiece Clean work...

Page 36: ... of the welding machine see Technical Data chapter 1 Err 3 x Welding machine excess temperature Allow the machine to cool down mains switch to 1 Err 4 x Low coolant level Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check excess current release on air cooling unit Err 5 x Error WF unit WF motor fault Speedometer error Check wire...

Page 37: ...e JOB JOB LIST JOB LIST m min Figure 7 1 Display Setting selection Reset to factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will be set to ex works 7 3 2 Resetting all JOBs m min JOB LIST JOB LIST Figure 7 2 Display Setting selection Reset to factory settings The RESET will be done after ...

Page 38: ...ters cannot be set Entry level is blocked disable access lock see chapter entitled key switch if available 7 4 1 Interface for mechanised welding WARNING No function of the external shut down devices emergency stop switch If the emergency stop circuit has been realised using an external shut down device via the interface for mechanised welding the device must be set for this setup If this is not o...

Page 39: ...g 4 min break Open circuit voltage 79V Mains voltage tolerances 3 x 400V 25 to 20 Frequency 50 60Hz Mains fuse safety fuse slow blow 3 x 35A Mains connection lead H07RN F4G6 Max connection power MIG MAG 20 7 kVA TIG 15 9 kVA MMA 21 6 kVA Recommended generator rating 29 1 kVA Cosϕ 0 99 Insulation class protection classification H IP 23 Ambient temperature 20 C to 40 C Machine torch cooling Fan gas ...

Page 40: ... 9 3 1 Liquid cooled Type Designation Item no MT550WR 3M PC2 EZA MIG welding torch POWERCONTROL 2 water cooled 094 500004 00700 9 4 Electrode holder workpiece lead Type Designation Item no WK70QMM 4M Z Workpiece cable grip 092 000013 00000 EH70QMM 4M Electrode holder 092 000011 00000 9 5 Remote control connection cable Type Designation Item no R10 Remote control with WF speed correction 090 008087...

Page 41: ...N SHOCK PROTECT Ram protection retrofit option 092 002154 00000 ON A INTERFACE Option retrofit for analog mech welding interface PHOENIX PROGRESS 092 001779 00000 9 7 Computer communication Type Designation Item no PC300 NET PC300 Net welding parameter software set incl cable and SECINT X10 USB interface 090 008265 00000 CD ROM PC300 NET PC300 Net Update on CD ROM 092 008172 00001 WELDQAS1 Station...