BOC Smootharc Elite TIG 230 AC/DC Operating Instructions Manual Download

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Operating instructions

Welding machine

Smootharc Elite TIG 230 AC/DC

099-000143-BOC01

16.11.2009

Summary of Contents for Smootharc Elite TIG 230 AC/DC

Page 1: ...Operating instructions Welding machine Smootharc Elite TIG 230 AC DC 099 000143 BOC01 16 11 2009...

Page 2: ...olely 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 T...

Page 3: ...he 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...

Page 4: ...piece lead general 21 5 5 Mains connection 22 5 5 1 Mains configuration 22 5 6 TIG welding 23 5 6 1 Connecting the welding torch and workpiece lead 23 5 6 2 Torch connection options and pin assignment...

Page 5: ...52 5 11 1 Remote control connection socket 19 pole 52 5 12 Advanced settings 53 5 12 1 Testing the machine fan 53 5 12 2 Limiting the mains current 10A 54 5 12 3 Protecting welding parameters from un...

Page 6: ...l 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 s...

Page 7: ...t 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 men...

Page 8: ...ich 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 Connectio...

Page 9: ...ny 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 workpie...

Page 10: ...ia 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 becom...

Page 11: ...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...

Page 12: ...s 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...

Page 13: ...nd Company Data Maintenance and Testing Warranty 3 2 2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction EC Low Voltage D...

Page 14: ...nnection for workpiece lead MMA Electrode holder or workpiece lead connection 3 Connection socket 5 pole 8 pole 12 pole 5 pole Standard TIG torch control lead 8 pole TIG Up Down or potentiometer torch...

Page 15: ...F HF Ignition type changeover switch HF HF ignition HF Liftarc contact ignition 4 8 pole connection socket Cooling unit control lead 5 Connection socket 19 pole Remote control connection 6 Main switch...

Page 16: ...3 2 3 2 4 4 0 10 20 30 30 20 10 mm mm DC DC AC AC AMP VOLT JOB AMP AMP AC T 2 30 mm mm AC special Automatic Puls sec Hz 0 10 20 30 30 20 10 S 6 7 4 3 2 1 10 5 9 11 12 8 Figure 4 3 Item Symbol Descript...

Page 17: ...rm Low noise level Switch display JOB number button Welding current display Welding voltage display 5 Display and select JOB number 6 50 50 75 75 100 100 125 125 150 150 175 175 200 200 Hz Hz Alternat...

Page 18: ...ng ranges 0 00 s to 5 0 s 0 1 s increments Pulse time Pulse time setting range 0 01 s to 9 99 s 0 01 s increments 5 sec TIG pulses The pulse time applies to the main current phase AMP for pulses TIG A...

Page 19: ...timisation of cleaning effect and fusion penetration characteristics 14 Alternating current frequency TIG AC 50 Hz to 200 Hz 1 Hz increments Constriction and stabilisation of the arc At a higher frequ...

Page 20: ...not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk from electrical cu...

Page 21: ...mponents 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 o...

Page 22: ...s Mains plug socket and lead must be checked regularly by an electrician 5 5 1 Mains configuration NOTE The machine may be connected and operated on all TN or TT networks with a neutral conductor and...

Page 23: ...the welding current connection socket and lock by turning to the right Remove yellow protective cap on G connecting nipple Screw welding torch shielding gas connection tightly onto the G connection n...

Page 24: ...us and even fatal injury Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air Place shielding gas cylinders in the holders provided f...

Page 25: ...gas cylinder 3 Output side of the pressure reducer 4 Cylinder valve Tighten the pressure reducer screw connection on the gas bottle valve to be gas tight NOTE Before connecting the pressure reducer t...

Page 26: ...ly insulated from persons animals or equipment during the setting procedure Press the torch trigger and set the shielding gas quantity with the flow gauge of the pressure reducer NOTE Rule of thumb fo...

Page 27: ...nt output wave form The all rounder for most applications TIG AC welding with sinusoidal current output wave form Low noise levels TIG Select and display operating mode spotArc spot time setting range...

Page 28: ...g the Switch display JOB number button until the respective signal lamp lights You can choose between 8 JOBs JOB 0 to 7 with the welding parameter rotary dial The parameters for the currently selected...

Page 29: ...values During welding actual values Welding current Welding voltage JOB number Parameter times Frequency balance Parameter currents not possible possible 5 7 2 1 Welding parameter setting The paramet...

Page 30: ...se or press the torch trigger depending on the operating mode selected 5 8 1 2 Liftarc ignition a b c Figure 5 7 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle...

Page 31: ...ectrode Increase parameter value more ignition power Reduce parameter value less ignition power 5 8 2 2 JOB operation JOB 1 to 7 Operating element Action Result x x Select ignition characteristics par...

Page 32: ...0 75 75 100 100 125 125 150 150 175 175 200 200 Hz Hz 1 0 1 0 1 6 1 6 2 4 2 4 3 2 3 2 4 4 0 10 20 30 30 20 10 mm mm DC DC AC AC AMP VOLT JOB AMP AMP AC T 2 30 mm mm AC special Automatic Puls sec Hz 0...

Page 33: ...e welding current increases with the adjusted up slope time to the main current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 2nd cycle Rele...

Page 34: ...witched off Step 2 Release torch trigger 1 The welding current increases with the set up slope time to the main current AMP Switching from main current AMP to secondary current AMP Press torch trigger...

Page 35: ...o 0 s to achieve an effective result Selecting and setting TIG spotArc Operating element Action Result Signal light comes on The spot time can be set for approx 4 s using the Welding parameter setting...

Page 36: ...ue set for the ignition current Istart HF is switched off The welding current increases in the adjusted up slope time to the main current AMP NOTE The process ends when the set SpotArc time elapses or...

Page 37: ...e 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 non latc...

Page 38: ...ent and pause current secondary current 5 8 6 1 Pulses thermal pulses I AMP t1 t2 t AMP Figure 5 14 Operating element Action Result AC special Automatic Puls sec Select TIG pulses function sec Signal...

Page 39: ...ec Select TIG automated pulses Press the TIG pulses button until the TIG automated pulses signal light comes on 5 8 6 3 AC pulses AC pulse max 50Hz Setting tpause tpuls t AMP AMP AMP AMP pulse current...

Page 40: ...sa This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced This is particularly useful in tacking and in spot welding Operating element Action Re...

Page 41: ...rs or potentiometers can be modified individually via torch modes Explanation of symbols for operating elements Symbol Description BRT 1 Press torch trigger BRT 1 Tap torch trigger BRT 2 Tap and press...

Page 42: ...T 1 AMP VOLT JOB Figure 5 16 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Torch configuration menu Set welding torch functions Torch mode setting Modes 1...

Page 43: ...g elements Welding current On Off BRT 1 Secondary current Latched mode 1 factory set BRT 1 Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch trigger 1...

Page 44: ...orch trigger 2 Functions mode Operating elements Welding current On Off BRT 1 Secondary current BRT 2 Secondary current tapping mode Latched mode 1 factory set BRT 1 Welding current On Off BRT 1 BRT 2...

Page 45: ...ed mode BRT 1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current tap...

Page 46: ...crease welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current BRT 2 Secondary cur...

Page 47: ...e Operating elements Welding current On Off BRT 1 Secondary current tapping mode Latched mode BRT 1 Increase welding current infinite adjustment Reduce welding current infinite adjustment 3 Potentiome...

Page 48: ...works TT 4 Welding current on off TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Increase JOB number TT 3 Decrease JOB number 2 TT 4 Welding current on off TT 1 Secondary...

Page 49: ...ellow insulating cap on the G connection nipple protects against electrical voltage and dirt 5 9 1 Connecting the electrode holder and workpiece lead 3 1 2 Figure 5 17 Item Symbol Description 0 1 Conn...

Page 50: ...tstart current signal light AMP comes on Set hotstart current The factory setting is a value as a percentage of the selected main current To set an absolute value for the hotstart current see chapter...

Page 51: ...chine Start stop welding operation TIG ActivArc welding is not possible in combination with the RTF 1 foot operated remote control 5 10 3 Manual remote control RTP 1 Functions TIG MMA Infinitely adjus...

Page 52: ...0V 0V 15V max 75mA 15V max 25mA START STOP AMP AMP PULS 10 100K A B C N P R S T U V D E F G H J K L M Figure 5 18 Item Pin Signal shape Designation 1 A Output Connection for cable screen PE 2 B L Outp...

Page 53: ...e switched on at the machine controls so that you can check that it is working correctly AMP VOLT JOB Figure 5 19 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised a...

Page 54: ...g machine to 10A in order to avoid triggering the fuse This restricts the welding machine s power input The maximum welding performance cannot be achieved when the current is limited to 10A AMP VOLT J...

Page 55: ...ck is active only the following parameters can be changed Welding current within a previously defined range Switch display Switch welding parameters JOBs AMP VOLT JOB Figure 5 21 Display Setting selec...

Page 56: ...activating and deactivating the access lock AMP VOLT JOB Figure 5 22 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Machine code Confirming the old machin...

Page 57: ...er in percentage display mode only the respective AMP signal light is lit AMP VOLT JOB Figure 5 23 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Settings...

Page 58: ...il the arc stabilises It always switches over to DC polarity after a few milliseconds AMP VOLT JOB Figure 5 24 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised acce...

Page 59: ...that they are fitted correctly and secured Operating message safety and adjustment devices Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls Transport ele...

Page 60: ...orised 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 warra...

Page 61: ...pressure can be built up e g top up water E2 Temperature error Allow machine to cool down E3 Electronics error Switch machine off and on again If the fault persists inform the service department E4 s...

Page 62: ...3 BOC01 16 11 2009 7 2 Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings AMP VOLT JOB Figure 7 1 Disp...

Page 63: ...ersion NOTE The query of the software versions only serves to inform the authorised service staff AMP VOLT JOB Figure 7 2 Display Setting selection Lock JOB menu Protect welding parameters from unauth...

Page 64: ...50A 140A Duty cycle DC at 40 C 35 DC 230A 180A 60 DC 160A 140A 100 DC 130A 110A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage DC 45V Mains voltage tolerances 1 x 230V 40...

Page 65: ...control e g connection cable 092 001470 00010 RA20 19POL 20M Remote control e g connection cable 092 001470 00020 RV5M19 19POLE 5M Extension cable 092 000857 00000 9 4 Transport vehicle Type Designati...

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