BOC Smootharc Elite MIG 451 Progress Pulse User manual

Operating instructions
Welding machine
Smootharc Elite MIG 451 Progress Pulse
Observe additional system documents!
099-004839-BOC01 10.11.2009

General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
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. 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 performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© 2009
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.

Dear Customer
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.
These machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore, we are
happy to provide you with a full 3-year warranty (five year warranty on transformers and rectifiers) according to
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 care, technical data as well as information regarding the warranty.
Please heed all these notes to ensure many years of safe operation of the machine.
Thank you for the trust that you have placed in us. We look forward to a long-term partnership
with you.
Yours sincerely
Bruce Currie
Marketing Director - South Pacific
BOC Limited

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................4
2Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions...........................................................................6
2.2 General...........................................................................................................................................8
2.3 Transport and installation.............................................................................................................11
2.3.1 Lifting by crane .............................................................................................................12
2.4 Ambient conditions.......................................................................................................................13
2.4.1 In operation...................................................................................................................13
2.4.2 Transport and storage ..................................................................................................13
3Intended use .........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.1.1 MIG/MAG standard welding .........................................................................................14
3.1.2 forceArc.........................................................................................................................14
3.1.3 MIG/MAG pulse welding...............................................................................................14
3.1.4 TIG (Liftarc) welding .....................................................................................................14
3.1.5 MMA welding................................................................................................................14
3.2 Use and operation solely with the following machines ................................................................15
3.3 Documents which also apply........................................................................................................15
3.3.1 Warranty .......................................................................................................................15
3.3.2 Declaration of Conformity.............................................................................................15
3.3.3 Welding in environments with increased electrical hazards.........................................15
3.3.4 Service documents (spare parts and circuit diagrams)................................................15
4Machine description – quick overview...............................................................................................16
4.1 Smootharc Elite MIG 451 Progress Pulse ...................................................................................16
4.1.1 Front view.....................................................................................................................16
4.1.2 Rear view......................................................................................................................18
5Design 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 connection ................................................................................................25
5.8 MIG/MAG welding........................................................................................................................26
5.8.1 Connection for workpiece lead .....................................................................................26
5.9 TIG welding..................................................................................................................................27
5.9.1 Welding torch connection .............................................................................................27
5.9.2 Connection for workpiece lead .....................................................................................28
5.10 MMA welding................................................................................................................................29
5.10.1 Connecting the electrode holder and workpiece lead ..................................................29
5.11 Interfaces .....................................................................................................................................30
5.11.1 Automation interface.....................................................................................................30
5.11.2 RINT X11 robot interface..............................................................................................31
5.11.3 BUSINT X10 Industrial bus interface............................................................................31
5.11.4 DVINT X11 Wire feed interface....................................................................................31
5.11.5 PC Interfaces................................................................................................................31
5.11.6 Setting options, internal................................................................................................31
5.11.6.1 Switching between Push/Pull and intermediate drive...................................31
5.12 Shielding gas supply....................................................................................................................32
5.12.1 Connecting the shielding gas supply............................................................................32

Contents
Notes on the use of these operating instructions
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6Maintenance, care and disposal.........................................................................................................33
6.1 General........................................................................................................................................33
6.2 Maintenance work, intervals ........................................................................................................33
6.2.1 Daily maintenance tasks ..............................................................................................33
6.2.2 Monthly maintenance tasks..........................................................................................33
6.2.3 Annual test (inspection and testing during operation)..................................................33
6.3 Repair Work.................................................................................................................................34
6.4 Meeting the requirements of RoHS .............................................................................................34
7Rectifying faults ...................................................................................................................................35
7.1 Customer checklist.......................................................................................................................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
8Technical data ......................................................................................................................................39
8.1 Smootharc Elite MIG 451 Progress Pulse...................................................................................39
9Accessories, options...........................................................................................................................40
9.1 System components ....................................................................................................................40
9.2 General accessories....................................................................................................................40
9.3 Welding torch...............................................................................................................................40
9.3.1 Liquid cooled ................................................................................................................40
9.4 Electrode holder / workpiece lead................................................................................................40
9.5 Remote control / connection cable ..............................................................................................40
9.6 Options.........................................................................................................................................41
9.7 Computer communication............................................................................................................41
9.8 Intermediate tube packages ........................................................................................................41
9.8.1 Liquid cooled ................................................................................................................41

Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
2.1 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.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general 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 must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
• Notes are highlighted using a "hand" symbol at the edge of the page.

Safety instructions
Notes on the use of these operating instructions
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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
Turn
Switch
01
Switch off machine
01
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/use

Safety instructions
General
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2.2 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!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
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.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding lines completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers 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 if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using safety
curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!

Safety instructions
General
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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!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and 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 work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!

Safety instructions
General
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CAUTION
Obligations of the operator!
In the European Economic Area (EEA), the relevant national version of the basic
guidelines must be followed and observed!
• National version of the basic guidelines (89/391/EEC) as well as the relevant individual
guidelines.
• 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
2128 Phone [phone].
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!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Electromagnetic interference!
The machines are intended to be used in industrial areas, according to IEC 60974-10. If
they are used in residential areas, for example, problems may occur with ensuring
electromagnetic compatibility.
• Check whether interference is caused to other machines!

Safety instructions
Transport and installation
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2.3 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!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
CAUTION
Risk of tipping!
There is a risk of the machine 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,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!

Safety instructions
Transport and installation
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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. Lifting principle)!
• Ensure that there is an even load distribution! Only use ring
chains or suspension ropes of the same length!
• Observe the lifting principle (see Fig.)!
• Remove all accessory components before lifting
(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!
min. 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 screw must be completely screwed in!
• The ring screw must be positioned flat onto and in full contact with the supporting surfaces!
• Check that the ring screws are securely fastened before use and check for any damage
(corrosion, deformation)!
• Do not use or screw in damaged ring screws!
• Avoid lateral loading of the ring screws!

Safety instructions
Ambient conditions
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2.4 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.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities 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 of 0.5 m from obstacles!
2.4.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C

Intended use
Applications
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3 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. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
3.1.1 MIG/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 stainless steel and aluminium thanks to
controlled drop transfer and targeted, adapted heat input.
3.1.4 TIG (Liftarc) welding
TIG welding process with arc ignition by means of workpiece contact.
3.1.5 MMA welding
Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between
a melting electrode and the molten pool. There is no external protection; any protection against the
atmosphere comes from the electrode.

Intended use
Use and operation solely with the following machines
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3.2 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 ;
3.3 Documents which also apply
3.3.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.3.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised 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 in
environments with an increased electrical hazard.
3.3.4 Service documents (spare parts and circuit diagrams)
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.

Machine description – quick overview
Smootharc Elite MIG 451 Progress Pulse
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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

Machine description – quick overview
Smootharc Elite MIG 451 Progress Pulse
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Item Symbol Description 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

Machine description – quick overview
Smootharc Elite MIG 451 Progress Pulse
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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
32 1
10
5
9
14
11
8
12
13
Figure 4-2

Machine description – quick overview
Smootharc Elite MIG 451 Progress Pulse
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Item Symbol Description 0
1
Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
2
analog
19-pole mechanised welding interface (analogue)
(See chapter entitled "Design and function > interfaces".)
3
7-pole connection socket (digital)
Wire feed unit connection
4
digital
7-pole connection socket (digital)
For connecting 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 Coolant water supply to the DV device (blue rapid-action closure coupling)
10 Conveyor rolls, fixed castors
11 Mains connection cable
12 Securing elements for shielding gas cylinder (strap/chain)
13 Cooling air outlet
14
Bracket for shielding gas cylinder

Design and function
General
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5 Design and function
NOTE
Observe documentation of other system components when connecting!
5.1 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!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Risk of burns on the welding current connection!
If the welding current connections are 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 of injury due to moving parts!
The wire feed units are equipped with moving parts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not 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
welding torch!
• Remove the counter pressure rollers from the wire feed unit if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and an
electrode holder remain connected to the machine, the open-circuit/welding voltage is
applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
CAUTION
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!