File 3

Operating instructions
Machines for MIG/MAG welding
Smootharc Elite MIG 351, 501

Smootharc Elite Wire Feeder 351/501
099-004934-BOC01
06.10.2009
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 +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. 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 Germanys 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
Contents
1 Contents ..................................................................................................................................................4
2 Safety instructions .................................................................................................................................7
2.1 Notes on the use of these operating instructions...........................................................................7
2.2 General...........................................................................................................................................9
2.3 Transport and installation.............................................................................................................12
2.3.1
Lifting by crane .............................................................................................................13
2.4 Ambient conditions.......................................................................................................................14
2.4.1
In operation...................................................................................................................14
2.4.2
Transport and storage ..................................................................................................14
3 Intended use .........................................................................................................................................15
3.1 Applications..................................................................................................................................15
3.1.1
MIG/MAG standard welding .........................................................................................15
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
4 Machine description quick overview...............................................................................................16
4.1 Smootharc Elite MIG 351 .............................................................................................................16
4.1.1
Front view .....................................................................................................................16
4.1.2
Rear view......................................................................................................................18
4.2 Smootharc Elite MIG 501 .............................................................................................................20
4.2.1
Rear view......................................................................................................................22
4.3 Smootharc Elite Wire Feeder 351/501.........................................................................................24
4.3.1
Front view .....................................................................................................................24
4.3.2
Rear view......................................................................................................................25
4.4 Machine control Operating elements ........................................................................................26
4.4.1
M2.40 welding machine control ....................................................................................26
5 Design and function.............................................................................................................................28
5.1 General.........................................................................................................................................28
5.2 Installation ....................................................................................................................................29
5.3 Machine cooling ...........................................................................................................................29
5.4 Workpiece lead, general ..............................................................................................................29
5.5 Welding torch cooling system ......................................................................................................30
5.5.1
General .........................................................................................................................30
5.5.2
List of coolants..............................................................................................................30
5.5.3
Adding coolant ..............................................................................................................31
5.6 Mains connection .........................................................................................................................32
5.6.1
Mains configuration.......................................................................................................32
5.7 Welding torch and workpiece line connection..............................................................................33
5.7.1
Intermediate tube package connection.........................................................................35
5.7.1.1 Wire feed unit ................................................................................................35
5.7.1.2 Welding machine...........................................................................................37
5.8 Shielding gas supply ....................................................................................................................38
5.8.1
Connecting the shielding gas supply ............................................................................38
5.8.2
Gas test ........................................................................................................................39
5.8.3
Setting the shielding gas quantity.................................................................................39
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Contents
5.9
10
Inserting the wire electrode.......................................................................................................... 40

5.9.1
Fixing the wire spool retainer (pre-tension adjustment) ............................................... 40
5.9.2
Spool brake setting....................................................................................................... 41
5.9.3
Inserting the wire spool ................................................................................................ 41
5.9.4
Changing the wire feed rollers...................................................................................... 42
5.9.5
Inching the wire electrode ............................................................................................43
5.9.6
welding task selection .................................................................................................. 44
5.9.6.1 Select JOB number (welding task)................................................................ 44
5.9.6.2 Setting the operating point (welding output) ................................................. 45
5.9.6.3 Setting the wire correction ............................................................................45
5.9.6.4 Setting the operating mode and runtime parameters ................................... 46
5.9.6.5 Setting the expert parameters....................................................................... 47
5.9.6.6 Welding parameter ignition time "tZn" diagram ............................................ 47
5.9.6.7 Explanation of symbols ................................................................................. 48
5.10 MIG/MAG functional sequences / operating modes .................................................................... 49
5.10.1 Explanation of signs and functions............................................................................... 49
5.10.2 Non-latched operation ..................................................................................................50
5.10.3 Latched operation......................................................................................................... 51
5.10.4 Spots ............................................................................................................................ 52
5.10.5 Interval.......................................................................................................................... 53
5.10.6 MIG/MAG automatic cut-out......................................................................................... 53
Maintenance, care and disposal......................................................................................................... 54
6.1 General ........................................................................................................................................ 54
6.2 Maintenance work, intervals ........................................................................................................ 54
6.2.1
Daily maintenance tasks .............................................................................................. 54
6.2.2
Monthly maintenance tasks.......................................................................................... 54
6.2.3
Annual test (inspection and testing during operation) .................................................. 54
6.3 Repair Work ................................................................................................................................. 55
6.4 Meeting the requirements of RoHS ............................................................................................. 55
Rectifying faults ................................................................................................................................... 56
7.1 Customer checklist....................................................................................................................... 56
7.2 Resetting the control (Reset all) .................................................................................................. 57
7.3 Check the machine type setting................................................................................................... 57
7.4 Setting the machine type ............................................................................................................. 57
Technical data ...................................................................................................................................... 58
8.1 Smootharc Elite MIG 351............................................................................................................. 58
8.2 Smootharc Elite MIG 501............................................................................................................. 59
8.3 Smootharc Elite Wire Feeder 351/501......................................................................................... 60
Accessories, options ........................................................................................................................... 61
9.1 General accessories .................................................................................................................... 61
9.1.1
Smootharc Elite MIG 351 .............................................................................................61
9.1.2
Smootharc Elite MIG 501 .............................................................................................61
9.2 Options......................................................................................................................................... 61
9.3 Wire feed rollers........................................................................................................................... 62
9.3.1
Wire feed rollers for steel wire...................................................................................... 62
9.3.2
Wire feed rollers for aluminium wire ............................................................................. 62
9.3.3
Wire feed rollers for cored wire .................................................................................... 62
9.3.4
Conversion sets............................................................................................................ 62
Appendix A ........................................................................................................................................... 63
10.1 Recommended settings ............................................................................................................... 63
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Contents
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Safety instructions
Safety instructions
2.1

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.
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Safety 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
Turn
Switch
Switch off machine
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
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Safety instructions
General
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!
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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!
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!
10
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Safety instructions
General
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 (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
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!
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Safety instructions
Transport and installation
2.3

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!
12
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Safety instructions
2.3.1
Lifting by crane
DANGER
min
.1
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.)!
75
Remove all accessory components before lifting
(e.g. shielding gas cylinders, tool boxes, wire feed units,
etc.)!
Fig. Lifting principle
Avoid jerky movements when raising or lowering!
Use shackles and load hooks of the appropriate size!
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!
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Safety instructions
Ambient conditions
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
14
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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. 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.
3.2
Use and operation solely with the following machines

Smootharc Elite
Wire Feeder 351/501
3.3
Documents which also apply
3.3.1
Warranty
MIG 351
;
MIG 501
;
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 60974, 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
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
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15
Machine description quick overview

Smootharc Elite MIG 351
4.1
4.1.1
Front view
2
3
6
7
11
8
10
12
Figure 4-1
16
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Item
Symbol Description 0
Wire feed unit
Lifting lug
Main switch, machine on/off
Signal light, Functional error

On when excess temperature detected
Step switch, welding voltage
Carrying handle
Cooling air inlet
Connection socket, workpiece lead

"Hard" choke tapping

"Medium" choke tapping
10

Choke tapping "soft"
11
Conveyor rolls, fixed castors
12
Conveyor rolls, guide castors
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17

4.1.2
Rear view
4
9
10
11
12
Figure 4-2
18
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Item
1
42V/4A
Mains connection cable
Button, Automatic cut-out of fan motor

Press to reset tripped circuit breaker
Earth cable connecting nipple

Connection of green-yellow earth cable from the intermediate tube package
Rapid-action closure coupling, red (coolant return)
Rapid-action closure coupling, blue (coolant supply)
Connector plug, welding current "+"

Welding current connection on wire feed unit
Intermediate tube package strain relief
10
Securing elements for shielding gas cylinder (strap/chain)
11
Cooling air outlet
12
Bracket for shielding gas cylinder
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Key button, automatic cutout

Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
7-pole connection socket
Wire feed unit control lead
19

4.2
10
8
9
12
11
Figure 4-3
20
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Item
Wire feed unit
Carrying handle
Main switch, machine on/off
Signal light, Functional error

On when excess temperature detected
Step switch, welding voltage "coarse"
Step switch, welding voltage



10
Cooling air inlet
11
Conveyor rolls, guide castors
12
Conveyor rolls, fixed castors
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4.2.1
Rear view
1
4
9
6
10
13
14
11
12
Figure 4-4
22
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Item
1
42V/4A
Mains connection cable
Button, Automatic cut-out of fan motor

Press to reset tripped circuit breaker


10
11
Cooling air outlet
12
13
Coolant tank cap
14
Coolant tank
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Key button, automatic cutout

Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
23

4.3
4.3.1
Front view
2
1
3
11
10
Figure 4-5
Item
24
Cover of the wire spool
Wire feed unit cover lock
Label, Wire feed parts subject to wear
Carrying handle
Spool holder
Wire delivery unit
Central connection for welding torch (Euro)

Integrated welding current, shielding gas and torch trigger
Rubber feet
10
11
Machine control
See Machine control operating elements chapter
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4.3.2
Rear view
Figure 4-6
Item


Connecting nipple G, shielding gas connection
4
5

Rubber feet
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Machine control Operating elements
4.4
4.4.1
M2.40 welding machine control
Figure 4-7
Item
1
Button, Wire inching
For inching the wire electrode when changing the wire spool
(speed = 6.0 m/min, constant).
The welding wire is inched into the tube package with the current off and without gas
being expelled.
This ensures a high degree of safety for the welder by preventing accidental ignition of
the arc.
Button, Gas test
The welding voltage and wire feed remain off when testing and setting the gas flow.
Pressing the key button once causes shielding gas to flow for approx. 25 seconds. The
button can be pressed again at any time to cancel the process.
Button, Welding task / operating point
The parameters are set on the rotary transducer
Wire speed display (m/min)
Welding current display (A)
Sheet metal thickness display (mm)
26
Display and select the jobs (welding tasks, selection via job list). Change
the JOBs by holding down the button (approx. 3 sec), LED flashes.
Button, Test welding parameters
Press the button and set the required welding voltage on the step switch at the same
time (the open-circuit voltage will be shown in the upper display; the wire speed,
welding current or panel thickness in the lower display).
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Item
Rotary dial, Wire speed / welding parameter setting

Infinite adjustment of the wire speed or welding current, sheet metal thickness, JOB
and runtime parameters such as gas post-flows, wire burn-back, etc.
Key button, Operating mode

Non-latched
Latched
10
11
12
13
14
MIG spots (parameter selection t1 is carried out using the "Runtime

parameters" button, setting on the "Rotary transducer".
Interval (parameter selection, t1 = pulse time, t2 = pulse pause, carried out
using "Runtime parameter" button, setting on the "Rotary transducer".
"Runtime parameters" button
The parameters are set on the rotary transducer
Gas post-flow time (0.0 s to 10.0 s)
Wire burn-back (-50% to +50%)
Spot time / pulse time (0.1 s to 5.0 s)
Pulse pause (0.1 s to 2.0 s)
Display, Top
Display of the welding voltage, correction value for the wire speed or parameter
designations for runtime parameters.
Display, Down
Display of wire feed speed, welding current, sheet metal thickness, JOB number and
runtime parameters.
Signal light Voltage
On when the welding voltage or open circuit voltage is displayed.
Signal light, Wire correction
On when the correction value of the wire speed is being displayed.
Signal light, HOLD
Lit:
Display shows the last parameters used for welding.
Not lit: Display shows the setpoint values or current values during welding.
Signal light, MANUAL
Signal light is on when the machine is not in JOB mode. All parameter settings are
carried out "manually" by the user (JOB 0).
Signal light, Choke tappings
Depending on the machine design, there are two or three workpiece connection
sockets on the welding machine (choke tappings). The machine displays the
recommended workpiece connection in JOB mode (see relevant images on the
connection sockets).
Choke tapping 1 (hard), workpiece lead connection socket
Choke tapping 2 (medium), workpiece lead connection socket
Choke tapping 3 (soft), workpiece lead connection socket
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Design and function

General
Design and function
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!
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Installation
5.2
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.
Safe operation of the machine must be guaranteed at all times.
5.3
Machine cooling
To obtain an optimal duty cycle from the power components, 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.
NOTE
In this machine series, the machine and torch cooling are temperature controlled. Fans
and coolant pump are therefore only switched on if required, or during the welding
process.
When the torch trigger is pressed and held down, the fans and the pump always run. If the torch
trigger is not being pressed, the fans and pump only run when the temperature exceeds a set
limit value.
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 and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!
Clean the connections!
Fix the workpiece lead securely!
Do not use structural parts of the workpiece as a return lead for the welding current!
Take care to ensure faultless power connections!
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Design and function

Welding torch cooling system
5.5
5.5.1
General
CAUTION
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage
and renders the manufacturer's warranty void!
Only use the coolant described in this manual (overview of coolants).
Do not mix different coolants.
When changing the coolant, the entire volume of liquid must be changed.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch (see overview of coolants).
Coolants with frost protection (KF 37E or KF 23E) must 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
observing the relevant safety data sheets (German waste code number: 70104)!
Coolant must not be disposed of together with household waste.
Coolant must not be discharged into the sewerage system.
Recommended cleaning agent: water, if necessary with cleaning agent added.
5.5.2
List of coolants
The following coolants may be used (for item nos., please see the Accessories chapter):
Coolant
Temperature range
KF 23E (Standard)
KF 37E
DKF 23E (for plasma machines)
30
-10C to +40C
-20C to +10C
0C to +40C
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5.5.3
Adding coolant
NOTE
After the initial filling, wait for at least one minute when the machine is switched on so
that the tube package is filled with coolant completely and without bubbles.
With frequent changes of torch and during the initial filling process, the cooling unit tank should
be topped up as necessary.
The unit is supplied ex works with a minimum level of coolant.
3
4
Figure 5-1
Item
Coolant tank cap
Coolant filter sieve
"Min" mark
Minimum coolant level
Coolant tank
Unscrew and remove the coolant tank sealing cover.

Check filter sieve insert for dirt, clean if necessary and reinsert into position.
Top up coolant to the filter sieve insert, close sealing cover again.
NOTE
The level of coolant must never fall below the min mark.
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Mains connection
5.6
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)!
Mains 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
L2
L3
PE
Figure 5-2
Legend
Item
L1
L2
L3
PE
Designation
Outer conductor 1
Outer conductor 2
Outer conductor 3
Protective conductor
Colour code
black
brown
grey
green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
For mains fuse protection, please refer to the Technical data chapter!
32
Insert mains plug of the switched-off machine into the appropriate socket.
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Welding torch and workpiece line connection
5.7

Depending on the wire electrode diameter and wire electrode type, either a spiral guide or a
plastic core with the appropriate interior diameter must be inserted into the welding torch!
Recommendation:
Use a spiral guide for welding hard wire electrodes (steel).
Use a plastic core for welding or brazing soft wire electrodes.
NOTE
Fault with the wire guide!
On delivery, the central connector (Euro) is fitted with a capillary tube for welding torches
with spiral guides. Conversion is necessary if a welding torch with a plastic core is used!
Welding torch with plastic core:
use with guide tube!
Welding torch with spiral guide:
use with capillary tube!
Preparation for connecting welding torches with a plastic core:
Push forward the capillary tube on the wire feed side in the direction of the central connector and
remove it there.
Slide plastic core guide tube off the central connector.
Carefully insert the central plug for the welding torch, with the still oversized plastic core, into the
central connector and screw together with crown nut.
Use a suitable tool to cut off the plastic core just before the wire feed roller, making sure not to pinch it.
Unfasten and remove the central plug on the welding torch.
Cleanly remove the burr from the separated end of the plastic core!
Preparation for connecting welding torches with a spiral guide:
Check that the capillary tube is correctly positioned in relation to the central connector!
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Design and function

4
5
6
4
6
Figure 5-3
Item
1
Central connection for welding torch (Euro)

Integrated welding current, shielding gas and torch trigger



Insert central plug of the welding torch into the central connector and screw together with crown nut.
Insert the cable plug of the workpiece lead into the connection socket for workpiece lead 1, 2 or 3
(depending on the application or shielding gas used) and lock by turning to the right.
Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure
couplings:
Return line red to rapid-action closure coupling, red (coolant return) and
supply line blue to rapid-action closure coupling, blue (coolant supply).
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5.7.1
Intermediate tube package connection

NOTE
The following section of the document applies only to decompact welding machines.
5.7.1.1
Wire feed unit
1
7
2
4
3
5
Figure 5-4
Item

Connecting nipple G, shielding gas connection
3
4


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Design and function

Insert the end of the tube package through the strain relief of the tube package and lock by turning to
the right.
Insert the plug on the welding current lead into the welding current connection socket "+" and lock.
Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure
couplings:
Return line red to rapid-action closure coupling, red (coolant return) and
supply line blue to rapid-action closure coupling, blue (coolant supply).
Insert cable plug on the control lead into the 7-pole connection socket and secure with crown nut (the
plug can only be inserted into the connection socket in one position).
Connect crown nut of the shielding gas line to the G connecting nipple.
Screw the eyelet of the earth lead on to the connecting nipple of the earth lead.
NOTE
A pilot static tube for a gas flow of 0-16 l/min is fitted on each wire feed unit as standard.
For applications where a higher gas flow rate is required (e.g. for aluminium), a pilot
static tube of 0-25 l/min (see accessories) should be installed.
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5.7.1.2
Welding machine
1
5
5
1
2
Figure 5-5
Item



Insert the end of the tube package through the intermediate tube package strain relief and lock by
turning to the right.
Insert the plug on the welding current lead into the connection socket "+" and lock.
Lock connecting nipples of the cooling water tubes into place in the corresponding rapid-action closure
couplings:
Return, red, to rapid-action closure coupling, red (coolant return) and
Return, blue, to rapid-action closure coupling, blue (coolant supply).
Insert the plug of the control cable into the 7-pole connection socket (digital) and secure with the
crown nut (the plug can only be inserted in one position into the connection socket).
Connect the crown nut on the shielding gas lead to the G" connecting nipple, connect the shielding
gas.
Screw the eyelet of the earth lead on to the connecting nipple of the earth lead.
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Design and function

Shielding gas supply
5.8

CAUTION
Faults in the shielding gas supply.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch
is a fundamental requirement for optimum welding results. In addition, a blocked
shielding gas supply may result in the welding torch being destroyed.
Always re-fit the yellow protective cap when not using the shielding gas connection.
All shielding gas connections must be gas tight.
5.8.1
Connecting the 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!
Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
Avoid heating the shielding gas cylinder!
NOTE
With compact machines, the shielding gas connection is made on the machine itself;
with decompact machines, on the intermediate tube package of the wire feed (see
"Intermediate tube package connection").
Figure 5-6
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Item
G connecting nipple
Shielding gas connection on the pressure reducer
Cylinder valve
Output side of the pressure reducer
Pressure reducer
Shielding gas cylinder
Place the shielding gas cylinder into the relevant cylinder bracket.
Secure the shielding gas cylinder using a securing chain.
NOTE
Before connecting the pressure reducer to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
5.8.2
5.8.3
Tighten gas hose on pressure reducer to be gas tight.
Gas test
Slowly open the gas cylinder valve.

Open the pressure reducer.
Switch on the power source at the main switch.
Initiate gas test function on the machine control.
Set the relevant gas quantity for the application on the pressure reducer.
Press
button. Gas flows for a maximum of 25 seconds or until
button is pressed again.
Setting the shielding gas quantity

Welding process
MAG welding
MIG brazing
MIG welding (aluminium)
TIG
Recommended shielding gas quantity

Wire diameter x 11.5 = l/min
Wire diameter x 11.5 = l/min
Wire diameter x 13.5 = l/min (100 % argon)
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!

The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
75% Ar/25% He
50% Ar/50% He
25% Ar/75% He
100% He
Factor
1.14
1.35
1.75
3.16
NOTE
Incorrect shielding gas setting!
If the shielding gas setting is too low or too high, this can introduce air to the weld pool
and may cause pores to form.
Adjust the shielding gas quantity to suit the welding task!
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Design and function

Inserting the wire electrode
5.9
5.9.1
Fixing the wire spool retainer (pre-tension adjustment)

NOTE
Because the spool brake also secures the wire spool retainer, the following steps are to
be carried out for every spool change and before every adjustment of the spool brake.
Figure 5-7
Item
1
Securing and braking unit
Allen screw
Securing the wire spool retainer and adjustment of the spool brake
Wire spool retainer
40
Open the wire feed unit.

Loosen the hexagonal socket screw of the securing and braking unit until the screw is free of the
thread in the wire spool retainer (do not remove it completely to prevent losing the small parts).
Pre-tension the securing and braking unit in the wire spool retainer by screwing the hexagonal socket
screw clockwise, making at least 4 complete turns (4 x 360).
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5.9.2
Spool brake setting
Figure 5-8
Item
Allen screw
Securing the wire spool retainer and adjustment of the spool brake
Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
NOTE
Do not jam the wire spool!
Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but
without it jamming during operation!
The fixing of the pin reel must be checked if the hexagonal socket screw is released.
See chapter Fixing of the pin reel (adjustment of the pre-tensioning)
5.9.3
Inserting the wire spool
Figure 5-9
Item
Carrier pin
For fixing the wire spool
Knurled nut
For fixing the wire spool
1
2
Loosen knurled nut from spool holder.

Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
Fasten wire spool using knurled nut.
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Design and function

5.9.4
Changing the wire feed rollers

NOTE
Unsatisfactory welding results due to faulty wire feeding!
Wire feed rollers must be suitable for the diameter of the wire and the material.
Check the roller label to verify that the rollers are suitable for the wire diameter.
Turn or change if necessary!
use V-Nut rollers with for steel wires and other hard wires,
use U-Nut rollers for aluminium wires and other soft, alloyed wires.
Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller.
Screw the drive rollers in place with knurled screws.
Figure 5-10
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5.9.5
Inching the wire electrode

CAUTION
Risk of injury due to welding wire escaping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily
injury including injuries to the face and eyes!
Never direct the welding torch towards your own body or towards other persons!
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!
Figure 5-11
Item
Pressure units
Clamping units
Wire feed nipple
Guide tube
Capillary tube or plastic core with support tube, depending on the torch
equipment
Extend and lay out the torch tube package.
Unfasten pressure units and fold out (clamping units and counter-pressure rollers will automatically flip
upwards).
Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive
roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
Press the clamping element with the counter pressure roller back downwards and fold the wire units
back up again (wire electrode should be in the groove on the drive roller).
The clamping pressure must be set on the adjusting nuts of the pressure units so that
the wire electrode is conveyed but will still slip through if the wire spool jams.
The clamping pressure for the front rollers (viewed from the direction of the feed) should always
be slightly higher than that of the rear rollers.
Press the wire inching button until the wire electrode projects out of the welding torch.
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Design and function

5.9.6
welding task selection
5.9.6.1
Select JOB number (welding task)

This microprocessor-controlled control works according to the one-dial operation principle.
Only the gas type, material type and wire electrode diameter should be set as the JOB number on the
control, as well as welding output via the step switch. This defines the welding task and the system
specifies the optimum wire feed speed for the required operating point after the "Test button" is pressed.
These settings are retained after the machine is switched off. After switching on again, the parameters
previously set can be used to continue welding.
The user has the option to correct the wire feed speed according to the welding task or individual
requirements.
The welding task setting can also be made using the two-dial operation principle, however. To do this, set
the "JOB 0" (manual / no program) from the JOB list, the welding voltage on the step switch, and the wire
speed on the rotary dial. Other parameters are set as described under "Using synergic mode".
Operating
element
Action
Xx
2 sec.
Result
Select "JOB". When the "JOB" LED lights, press and hold down
the button.
"JOB" LED flashes.
The welder uses the filler material inserted and the connected shielding gas to select the JOB number
according to the "JOB-LIST". The "JOB-LIST" is a sticker fixed near the wire feed drive unit.
Set JOB number (0-24).
Confirm selection.
1x
Figure 5-12
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5.9.6.2
Setting the operating point (welding output)
NOTE
The operating point setting in JOB "0" (manual) is carried out as described in the chapter
of the same name for control M2.20. The following settings are therefore only intended
for work in JOBs 1-24.
Operating
element
Action
Result
Select the parameter via which the welding output is to be set:
nx
using the panel thickness

using the wire speed
using the welding current
Hold down the "TEST" button and at the same time set the operating
point on the step switch.
The display shows the required parameters and the open circuit
voltage.
If the "Volt" and "Wire feed correction" diodes are flashing, this indicates
an error (e.g. short circuit between torch and workpiece, inductivity
error, etc). To correct the error, press "TEST" again.
If the operating mode has already been selected, all the necessary settings will have been
activated and welding can be started.
5.9.6.3
Setting the wire correction

The wire speed (arc length) can be modified using the wire correction if required.
Operating
Action
Result
element
Set the wire correction value
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Design and function

5.9.6.4
Setting the operating mode and runtime parameters
NOTE
The parameter values set are preset in the JOB and can be modified if necessary.
Operating
element
Action
nx
nx
Result
Select operating mode:
Non-latched
Latched
Spots
Interval
Select welding parameter:
Set gas post-flow time "GnS"
(0.0 s to 10.0 s)
Set wire burn-back time "drb" (-50% to 50%)
Spot/interval time "t1" (0.1 s to 5.0 s)
Interval/pause "t2" (0.1 s to 2.0 s)
The selected parameter is shown on the display
Set the parameter chosen
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5.9.6.5
Setting the expert parameters
NOTE
The parameter values set are preset in the JOB and can be modified if necessary.
Operating
element
Action
Result
1x
Select expert parameters.

The key combination must be pressed within 3 seconds.
1x
2x
nx
Select expert parameters:

Gas pre-flow time "GvS" (0 s to 10 s)
Wire creep speed "On" 0.5 24 m/min
Ignition time "tZn" (0 ms to 500 ms)
The selected parameter is shown on the display.
Set the parameter chosen.
5.9.6.6
Welding parameter ignition time "tZn" diagram
NOTE
In the ignition time, the wire feed continues to run at creep speed after the arc is ignited;
the ignition behaviour is improved with the optimum setting.
The factory setting is that the ignition time is already optimally preset for various materials. The
process described below is always used if there is a pause between welding processes of not
less than 1.5 seconds.
Figure 5-13
Legend with an explanation of symbols can be found in the MIG/MAG function sequences /
operating modes chapter.
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Design and function

5.9.6.7 Explanation of symbols
Symbol Meaning
"GnS" - Gas post-flows
"drb" - Wire burn-back
"t1" - Spot time
"t2" - Interval time
"GvS" - Gas pre-flows
"On" - Wire creep
"tZn" - Ignition time
"tyP" - Machine type (type table, see chapter "Reset to factory settings")
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MIG/MAG functional sequences / operating modes
5.10

NOTE
There are optimum pre-sets for welding parameters such as gas pre-flow and free-burn,
etc. for numerous applications (although these can also be changed if required).
5.10.1 Explanation of signs and functions

Symbol
Meaning
Press torch trigger
Release torch trigger
Tap torch trigger (press briefly and release)
Shielding gas flowing
Welding output
Wire electrode is being conveyed
Wire creep
Wire burn-back
Gas pre-flows
Gas post-flows
Non-latched
Latched
t
t1
t2
tZn
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Time
Spot time
Interval pause
Ignition time
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5.10.2 Non-latched operation
Figure 5-14
Step 1
Press and hold torch trigger.
Shielding gas is expelled (gas pre-flows).
Wire feed motor runs at "creep speed".
Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
Changeover to the pre-selected wire speed after the set ignition time (tZn).
Step 2
Release torch trigger.
WF motor stops.
Arc is extinguished after the pre-selected wire burn-back time elapses.
Gas post-flow time elapses.
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5.10.3 Latched operation
Figure 5-15
Step 1
Arc ignites when the wire electrode makes contact with the workpiece; welding current flows.
Step 2
Release torch trigger (no effect).
Step 3
Press torch trigger (no effect).
Step 4
WF motor stops.
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Design and function

5.10.4 Spots
Figure 5-16
1. Start
The WF stops after the set spot time elapses.
2. End
NOTE
When the torch trigger is released, the welding process is also interrupted even before
the spot time elapses.
With fast tacking (time between two welding process under approx. 1.5 seconds) the gas
pre-flow, the creep process and also the ignition time (tZn) are not required.
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5.10.5 Interval
Figure 5-17
1. Start
Wire-feed motor runs at "creep-start speed".
The wire feed stops after the pulse time expires.
Arc is extinguished after the wire burn-back time elapses.
The process is repeated after the pause time elapses.
2. End
Wire feed stops.
Arc is extinguished after the wire burn-back time elapses.
NOTE
When the torch trigger is released, the welding process is also interrupted even before
the spot time elapses.
With fast tacking (time between two welding process under approx. 1.5 seconds) the gas
pre-flow, the creep process and also the ignition time (tZn) are not required.
5.10.6 MIG/MAG automatic cut-out

NOTE
The welding machine ends the ignition process or the welding process with an
Ignition fault (no welding current flows within 5 s after the start signal).
Arc interruption (arc is intrerupted for longer than 3 s).
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Maintenance, care and disposal

General

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!
Wait for 4 minutes until the capacitors have discharged!
6.1
General
When used in the specified environmental conditions and under normal operating conditions, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as described below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2
Maintenance work, intervals
6.2.1
Daily maintenance tasks
6.2.2
Monthly maintenance tasks
6.2.3
Mains supply lead and its strain relief

Welding current cables (check that they are fitted correctly and secured)
Gas tubes and their switching equipment (solenoid valve)
Gas cylinder securing elements
Operating, message, safety and adjustment devices
Other, general condition
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 and their connections for impurities
Annual test (inspection and testing during operation)

NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
able to recognise the dangers that can occur while testing welding power sources as
well as possible subsequent damage and who is able to implement the required safety
procedures.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
The former term of repetition test has been replaced due to a change in the corresponding standard with
Inspection and testing during operation.
In addition to the regulations on the test given here, the relevant local laws and regulations must also be
observed.
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Repair Work
6.3
Repair Work
DANGER
Repair and maintenance work may only be performed by qualified authorised 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 well as the type designation and item
number of the spare part.
6.4
Meeting the requirements of RoHS

We, EWM HIGHTEC Welding GmbH Mndersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
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Rectifying faults
Customer checklist
Rectifying faults
7.1
Customer checklist
Error
Possible cause
Remedy
No wire feed
Spatter has blocked the

contact nozzle
Feed roller is slipping
Clean nozzle, spray on separating agent
Wire coil brake too strong

Torch defective
Check contact pressure roller. Check for

wear and tear and replace if necessary
Check automatic cut-out on the wire feed
motor
Unfasten contact nozzle, cut off wire after
bent section
Set coil brake correctly
Replace
Core or nozzle blocked
Clean, replace if necessary
Tube package bent too much
Stretch out tube package
Wire feed coils blocked or

damaged
Wire coil brake too strong
Contact nozzle too small
Clean, replace if necessary
Wire feed motor is not turning

over
Wire bent
Loop in wire
Wire feed irregular
Weld seam porous
Incorrect shielding gas setting

Gas cylinder empty
Electrode is projecting too far
forwards
Air current
Poor wire quality
Very dirty workpiece
Local overheating of the
workpiece
Gas line is drawing in air
Machine will not switch

on
56
No mains voltage
Set coil brake correctly

Check, replace if necessary
Correct: Rule of thumb "Wire diameter *10 =
flow in l/min"
Change
Move torch closer to weld seam
Shield welding area
Use high quality wire, store in a dry and
clean location.
Clean workpiece first
Include occasional pauses in welding to
allow the workpiece to cool down.
Check seal tightness on lines, seal / replace
if necessary.
Power source faulty
Check the mains fuses, replace as

necessary
Contact service
Strong spatter
Blow effect
No gas
Connect workpiece line more appropriately

Set gas quantity to match the application
No welding current
Workpiece line has no or poor

contact
Power source overheating
Check connection
Wire feed or gas valve

faulty
Electronic control
Allow machine to cool down

Check line connections, replace electronics
if necessary. Contact service
099-004934-BOC01
06.10.2009
Rectifying faults
Resetting the control (Reset all)
7.2
Resetting the control (Reset all)

NOTE
All user settings will be overwritten with factory settings and must therefore be checked
afterwards, or set up again!
After resetting the machine control to the factory settings, it is essential that the machine
type used is checked and reset if necessary.
Operating
element
Action
Result
Switch off the welding machine.
1x
Press and hold both buttons.
+
Switch on the welding machine, "rES" is shown briefly on the display.
1x
7.3
Check the machine type setting

NOTE
When first switching on after resetting to the factory settings, the machine type is
displayed under the designation "tyP".
If an incorrect machine type is shown, it must be reset.
tyP 00
tyP 01
tyP 02
tyP d02
tyP d03
tyP d04
7.4
SATURN 251
SATURN 301
SATURN 351
WEGA 351, SATURN 351 DG (Smootharc Elite MIG 351)
WEGA 401,451
WEGA 501,601 (Smootharc Elite MIG 501)
Setting the machine type

Operating
element
Action
Result
Switch off the welding machine.
1x
Press and hold both buttons.
Switch on the welding machine, "Anl" is shown on the display.

1x
Whilst "Anl" is being displayed, set the machine type:
0 - SATURN 251
2 - SATURN 351
1 - SATURN 301
3 - WEGA (Smootharc Elite)
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57
Technical data
Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1

Switching steps
Welding current setting range
30 A - 350 A
Duty cycle at 40C ambient temperature

45 %
350 A
60 %
300 A
100 %
230 A

52,5 %
350 A
70 %
300 A
100 %
250 A
Open circuit voltage

Mains connection lead
Mains voltage (tolerances)
15.5-41 V
H07RN-F4G4
3 x 400 V (+/- 15%)
Frequency
50/60 Hz
Mains fuse (slow-blow safety fuse)
3 x 25 A
Max. connected power
16 kVA
Workpiece lead
50 mm
Recommended generator power

Cos
Weight
Dimensions (L x W x H in mm)
Insulation class/protection classification
Ambient temperature
Machine cooling / torch cooling
Constructed to standards
58
16
21,5 kVA
0.95
125 kg
1100 x 550 x 940
H/IP 23
-20C to +40C
Fan / gas
IEC 60974-1, -10
/
099-004934-BOC01
06.10.2009
Technical data
8.2

Switching steps
36 (3x12)
Welding current setting range
50 - 500 A

60%
500 A
100%
400 A

70%
500 A
100%
400 A
Open circuit voltage

Mains voltage (tolerances)
Frequency
Mains fuse
(safety fuse, slow-blow)
Max. connected power
3 x 400 V (+/- 15 %)
50 / 60Hz
3 x 32 A
27,5 kVA
Workpiece lead
95 mm2
Recommended generator power
32 kVA
Cos
Max. tank capacity
0,95
9l
Flow rate (max.)
5 l/min
Initial pressure (max.)
3.5 bar
Weight
200 kg
Dimensions (L/W/H in mm)

Insulation class/protection classification
Ambient temperature
Machine cooling / torch cooling
099-004934-BOC01
06.10.2009
16,5 - 49,5 V
950 x 560 x 1010

H / IP 23
-20 C to +40 C
Fan / water
IEC 60974-1, -10
/
59
Technical data
8.3

Supply voltage
Max. welding current at 60% DC
Wire-feed speed
Standard WF roller fitting
Drive
Torch connection
Protection classification
520 A
0.5 m/min to 24 m/min
1.0 + 1.2 mm (for steel wire)
4-roller (37mm)
Welding torch central connection (Euro)
IP 23
Ambient temperature
-20C to +40C
Dimensions (L x W x H) [mm]
690 x 300 x 410
Weight
60
42 V AC
approx. 18 kg
IEC 60974-1, -5, -10 /
099-004934-BOC01
06.10.2009
Accessories, options
General accessories
9.1
General accessories
Type
KF 23E-10
KF 37E-10
TYP 1
AK300
G1 2M G1/4 R 2M
GS16L G1/4" SW 17
GS25L G1/4" SW 17
9.1.1
092-000003-00000
094-000579-00000
094-000579-00001
094-000579-00002
Workpiece cable, grip

Intermediate hose package, water
092-000013-00000
094-000406-00000
094-000406-00001
094-000406-00002
Designation
Optional wheel assembly retrofit kit Drive4/4S
Optional wheel assembly retrofit kit for DRIVE4L
Retrofit option, wire creep rotary dial
Item no.
090-008035-00000
090-008151-00000
092-001102-00000
Options
Type
ON RMSDDV1
ON RMSDV2
ON WIRE CREEP POTI
M1.02
ON FSB WHEELS W/T/P
WEGA 351, 401, 451
ON FILTER W
ON HOSE/FR MOUNT
ON HOSE/FR MOUNT DK
ON TOOL BOX
ON HOLDER GAS BOTTLE
<50L
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06.10.2009
Workpiece cable, clamp

Intermediate hose package, gas

WK70QMM 4M Z
ZWIPA 70QMM MIG W 1M
9.2
Item no.
094-000530-00000
094-006256-00000
094-014499-00000
094-001803-00001
094-000010-00001
094-000914-00000
094-001100-00000

WK50QMM 4M KL
50QMM MIG G 1M
50QMM MIG G 5M
50QMM MIG G 10M
9.1.2
Designation
Coolant (-10 C), 9.3 l
Coolant (-20 C), 9.3 l
Frost protection tester
Adapter for K300 basket coil
Gas hose
Pilot static tube
Pilot static tube
Retrofit option for locking brake for machine wheels 092-002110-00000

Retrofit option contamination filter for air inlet
Optional holder for tubes and remote control for
machines without star handle
Optional holder for tubes and remote control for
machines with star handle
Retrofit option tool box
Retrofit option holding plate for gas bottle <50 L
092-002091-00000
092-002116-00000
092-002117-00000
092-002138-00000
092-002151-00000
61
Wire feed rollers
9.3
Wire feed rollers
9.3.1
Wire feed rollers for steel wire

Type
FE 2DR4R 0,6+0,8
FE 2DR4R 0,8+1,0
FE 2DR4R 0,9+1,2
FE 2DR4R 1,0+1,2
FE 2DR4R 1,2+1,6
FE/AL 2GR4R
9.3.2
Item no.
092-000869-00000
092-000848-00000
092-000849-00000
092-000870-00000
Designation
Drive rollers, 37 mm, cored wire
Counterpressure rollers, knurled, 37mm
Item no.
092-000834-00000
092-000835-00000
092-000836-00000
092-000837-00000
092-000838-00000
Designation
Conversion kit, 37mm, 4-roller drive on non-toothed
rollers (steel/aluminium)
Conversion kit, 37mm, 4-roller drive for aluminium
Conversion kit, 37mm, 4-roller drive for cored wire
Item no.
092-000845-00000
092-000831-00000
092-000832-00000
092-000833-00000
Conversion sets
Type
URUE VERZ>UNVERZ FE/AL
4R
URUE AL 4ZR4R 0,8+1,0
URUE ROE 2DR4R
0,8/0,9+0,8/0,9
URUE ROE 2DR4R
1,0/1,2+1,4/1,6
URUE ROE 2DR4R
1,4/1,6+2,0/2,4
URUE ROE 2DR4R 2,8+3,2
62
Designation
Twin rollers, 37 mm, for aluminium
Wire feed rollers for cored wire

Type
ROE 2DR4R 0,8/0,9+0,8/0,9
ROE 2DR4R 1,0/1,2+1,4/1,6
ROE 2DR4R 1,4/1,6+2,0/2,4
ROE 2DR4R 2,8+3,2
ROE 2GR4R
9.3.4
Item no.
092-000839-00000
092-000840-00000
092-000841-00000
092-000842-00000
092-000843-00000
092-000844-00000
Wire feed rollers for aluminium wire

Type
AL 4ZR4R 0,8+1,0
AL 4ZR4R 1,0+1,2
AL 4ZR4R 1,2+1,6
AL 4ZR4R 2,4+3,2
9.3.3
Designation
Drive rollers, 37 mm, steel
Counterpressure rollers, smooth, 37mm
092-000867-00000
092-000846-00000
092-000847-00000
092-000868-00000
092-000830-00000
099-004934-BOC01
06.10.2009
Appendix A
Recommended settings
10
Appendix A
10.1
Figure 10-1
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63
Appendix A
Figure 10-2
64
099-004934-BOC01
06.10.2009

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Operating instructions

Machines for MIG/MAG welding

Smootharc Elite MIG 351, 501

Inserting the wire electrode.......................................................................................................... 40

Notes on the use of these operating instructions

Switch off machine

NAVIGATION (Navigating in the menu)

EXIT (Exit the menu)

Interruption in the menu display (other setting options possible)

Transport and installation

Risk of injury during lifting by crane!

Risk of injury due to unsuitable ring screws!

Transport and storage

MIG/MAG standard welding

Use and operation solely with the following machines

Documents which also apply

Welding in environments with increased electrical hazards

Service documents (spare parts and circuit diagrams)

Machine description quick overview

Machine description quick overview

Smootharc Elite MIG 351

Machine description quick overview

Wire feed unit

Main switch, machine on/off

Signal light, Functional error

Step switch, welding voltage

Cooling air inlet

Connection socket, workpiece lead

Connection socket, workpiece lead

Connection socket, workpiece lead

Conveyor rolls, fixed castors

Conveyor rolls, guide castors

Machine description quick overview

Machine description quick overview

Mains connection cable

Button, Automatic cut-out of fan motor

Earth cable connecting nipple

Rapid-action closure coupling, red (coolant return)

Rapid-action closure coupling, blue (coolant supply)

Connector plug, welding current "+"

Intermediate tube package strain relief

Securing elements for shielding gas cylinder (strap/chain)

Cooling air outlet

Bracket for shielding gas cylinder

Key button, automatic cutout

Machine description quick overview

Smootharc Elite MIG 501

Machine description quick overview

Wire feed unit

Main switch, machine on/off

Signal light, Functional error

Step switch, welding voltage "coarse"

Step switch, welding voltage

Connection socket, workpiece lead

Connection socket, workpiece lead

Connection socket, workpiece lead

Cooling air inlet

Conveyor rolls, guide castors

Conveyor rolls, fixed castors

Machine description quick overview

Machine description quick overview

Mains connection cable

Button, Automatic cut-out of fan motor