BOC MIG 250C Operating Manual
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BOC MIG 250C Operating Manual

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MIG 250C
Operating manual
Machine comes with side tray

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Summary of Contents for BOC MIG 250C

  • Page 1 MIG 250C Operating manual Machine comes with side tray...

  • Page 2: Welcome To A Better Way Of Welding

    This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’), as general information and does not contain and is not to be taken as containing any specific recommendation. The document has been prepared in good faith...

  • Page 3: Table Of Contents

    BOC Smootharc Advance II MIG 250C Operating manual Recommended Safety Guidelines and Precautions Health Hazard Information Contents. Personal Protection Electrical shock User Responsibility MIG Process Introduction to Metal Inert Gas (MIG) Introduction to Flux Cored Arc Welding (FCAW) Introduction to Metal Cored Arc Welding (MCAW)

  • Page 4: Recommended Safety Guidelines And Precautions

    BOC Smootharc Advance II MIG 250C Operating manual 1.0 Recommended Safety Guidelines and Precautions Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming from welding process Some safety precautions BOC recommends are as follows: Welding arc rays →...

  • Page 5: Health Hazard Information

    BOC Smootharc Advance II MIG 250C Operating manual Health Hazard Information → Fumes from the welding of some metals could have an adverse effect on your health. Don’t breathe them in. If you are welding on material The actual process of MIG welding is one that can cause a variety of such as stainless steel, nickel, nickel alloys or galvanised steel, hazards.

  • Page 6: Electrical Shock

    BOC Smootharc Advance II MIG 250C Operating manual Electrical shock BOC stock a huge range of personal protective equipment. This combined with BOC’s extensive Gas and Gear network ensures fast, reliable service → Never touch ‘live’ electrical parts throughout the South Pacific.

  • Page 7: Mig Process

    BOC Smootharc Advance II MIG 250C Operating manual 2.0 MIG Process Typical MIG set up Torch Torch trigger Shroud Gas diffuser Contact tip Welding wire Shielding Weld Droplets Weld pool Introduction to Metal Inert Gas (MIG) Each gas or gas mixture has specific advantages and limitations. Other...
  • Page 8 BOC Smootharc Advance II MIG 250C Operating manual Extended self shielded flux cored wire nozzle Unlike MIG, which uses a solid consumable filler wire, the consumable One often quoted property of fluxed cored wires are their higher used in FCAW is of tubular construction, an outer metal sheath being deposition rates than solid MIG wires.

  • Page 9: Introduction To Metal Cored Arc Welding (Mcaw)

    BOC Smootharc Advance II MIG 250C Operating manual Process Schematic Diagram for MIG / FCAW and MCAW Gas hose Continous wire Wire feed unit Power cable Torch conduit Gas cylinder Welding torch Workpiece Earth clamp Power source Return cable 2.3 Introduction to Metal Cored efficiency differs by wire type and manufacturer it is typically between 75–85%.
  • Page 10 BOC Smootharc Advance II MIG 250C Operating manual Schematic of Dip Transfer Short circuit Necking Arc re-ignition Arc established Arc gap shortens Short circuit Time Current (A) Voltage (V) Short circuit cycle Arcing cycle Unlike MIG, which uses a solid consumable filler wire, the consumable...
  • Page 11 BOC Smootharc Advance II MIG 250C Operating manual Schematic of Globular Transfer Schematic of Spray Transfer Gas shroud Shielding gas Wire Droplets Weld Splatter Large droplet Workpiece Workpiece Globular Transfer welding. The main exception is aluminium and its alloys where, primarily...

  • Page 12: Fundamentals Of Mig, Fcaw And Mcaw

    The result of this is excessive tip wear and increased wear in the liners. the BOC range of MIG wires for the most common materials. If the helix is too large the wire will leave the tip with a corkscrew effect.
  • Page 13 BOC Smootharc Advance II MIG 250C Operating manual Selection of the Correct Power Source Selection of the Correct Shielding Gas Power sources for MIG welding is selected on a number of different The selection of the shielding gas has a direct influence on the criteria, including: appearance and quality of the weldbead.

  • Page 14: Mma Process

    Even welders with some experience will benefit from the information in BOC supplies a popular range of arc welding machines. Machines this manual. range from small portable welders that operate from standard 240 Volt household power to heavy-duty welders used by the largest...

  • Page 15: Welding Technique

    BOC with their typical areas of application. Successful welding depends on the following factors: For example, the average welder will carry out most fabrication using mild steel and for this material has a choice of various standard BOC → selection of the correct electrode electrodes, each of which will have qualities suited to particular tasks.
  • Page 16 BOC Smootharc Advance II MIG 250C Operating manual Electrodes and Typical Applications Recommended Electrode Sizes Name Application Average Thickness Maximum Recommended Class. of Plate or Section Electrode Diameter BOC Smootharc 13 E6013 A premium quality electrode for general ≤1.5 mm 2.0 mm...
  • Page 17 Minimum Maximum lost. Certain BOC electrodes have been specially designed for ‘touch’ welding. These electrodes may be dragged along the work and a perfectly sound weld is produced.

  • Page 18: Types Of Joints

    BOC Smootharc Advance II MIG 250C Operating manual Layers Weld Beads Butt Welding Electrode Angle for 1st and 2nd Layers Electrode Angle for Subsequent Layers Face Reinforcement Weld Face Layers Weld Beads Layers Weld Beads Root Face Root Gap Electrode...

  • Page 19: Fillet Welds

    BOC Smootharc Advance II MIG 250C Operating manual Welding Progression Angle General notes on Butt Welds necessarily penetrate the full thickness of either member. It is important that the parts to be joined be clean, close fitting, and that all the edges The first run in a prepared butt weld should be deposited with an on which welding is to be carried out are square.
  • Page 20 BOC Smootharc Advance II MIG 250C Operating manual Convex Fillet Weld Concave Fillet Weld Actual Throat Actual Throat & Effective Throat & Effective Throat Actual Throat Actual Throat Convexity Convexity Concavity Concavity Effective Throat Effective Throat Size Size Lengh Lengh...

  • Page 21: Typical Defects Due To Faulty Technique

    Many of these welding technique problems weaken the and smooth (only BOC Smootharc 13 is suitable for this position). weld and can cause cracking. Other problems that can occur which can...
  • Page 22 BOC Smootharc Advance II MIG 250C Operating manual Slag Inclusions Undercutting Lack of Fusion This defect can be prevented by: → using a travel speed slow enough so that the weld metal can completely fill all of the melted out areas of the base metal.

  • Page 23: General Welding Information

    BOC Smootharc Advance II MIG 250C Operating manual 4.0 General Welding Information Recommended Welding Parameters Argoshield® Light [Mild Steel Solid Wire] Indicative Welding Parameters Dip Transfer Material thickness (mm) 1–1.6 Wire diameter (mm) 0.8–0.9 0.8–0.9 0.8–0.9 0.9–1.0 Voltage (volts) 14–16 16–17 16–18...
  • Page 24 BOC Smootharc Advance II MIG 250C Operating manual Argon [Aluminium Solid Wire] Indicative Welding Parameters Solid Wire Material thickness (mm) Welding position Horizontal Horizontal Horizontal Wire diameter (mm) Current (amps) 160–180 210–220 215–225 Voltage (volts) 21–23 22–24 22.5–24.5 Wire feed speed (m/min) 8.0–9.0...

  • Page 25: Correct Application Techniques

    BOC Smootharc Advance II MIG 250C Operating manual 5.0 Correct Application Techniques Electrical stickout Contact Tube Setback Standoff Distance Visible Stickout Arc length Electrical Stickout Gas Nozzle Contact Tube Consumable Electrode Workpiece Correct Application Techniques Flux cored welding with cored wires takes place normally with the drag technique.
  • Page 26 BOC Smootharc Advance II MIG 250C Operating manual Electrical stickout Travel speed Short Normal Long Slow Normal Fast Slow Normal Fast Short Normal Long Electrical stickout The electrical stickout is the distance between the end of the contact tip and the end of the wire. An increase in the electrical stickout results in an increase in the electrical resistance.

  • Page 27: Package Contents

    BOC Smootharc Advance II MIG 250C Operating manual 6.0 Package Contents Package Contents ✓ Power source with input cable MIG Torch Binzel MB 36KD ✓ BOC Argon regulator ✓ Work return lead ✓ 1× gas hose with quick release Wire feed rollers Knurled 0.8-0.9/1.0-1.2...

  • Page 28: Installation

    BOC Smootharc Advance II MIG 250C Operating manual 7.0 Installation Installation for MIG/MAG process Installation for MMA process 250C Smootharc Smootharc Advance Advance Advance Advance m/min CRATER INDUCTANCE ARC CURRENT VOLTAGE INDUCTANCE 9 For torch negative, couple the short mechanical connector...

  • Page 29: Operation Set-Up

    BOC Smootharc Advance II MIG 250C Operating manual 8.0 Operation Set-up Front of MIG 250C Inside of MIG 250C Wir e Inch Process selection switch (MMA, MIG) Voltage Wire feed speed and Arc current Inductance Positive dinse connector Negative dinse connector...

  • Page 30: Control Panel

    The wire feed control adjusts the speed that the wire is fed through the The easy-to-operate and understand machine front panel includes two MIG torch. The BOC Smootharc ADVANCE wire feed control is stepless LED displays for welding voltage and current/wire feed speed.

  • Page 31: Inductance

    BOC Smootharc Advance II MIG 250C Operating manual Inductance Inductance is defined as the rise in current to above normal, in any Summarising, inductance has the following effects: electrical circuit that results in the melting of the wire at some point.

  • Page 32: Troubleshooting And Fault Finding

    BOC Smootharc Advance II MIG 250C Operating manual 10.0 Troubleshooting and Fault Finding Power source Component Fault symptom Cause Primary cable No or low welding output Bad or incorrect primary connection, lost phase Earth cable and clamp Arc will not initiate...

  • Page 33: Replacement Parts

    BOC Smootharc Advance II MIG 250C Operating manual 11.0 Replacement Parts MIG 250C Suitability Description Part No. Torch ✓ Binzel MB Grip 36KD Air Cooled 3m 014.0234 Wire Feed Rollers ✓ Self-Shielded Flux Cored Knurled 0.8–0.9 ADVANCEKNROL0809 ✓ Knurled 1.0–1.2 ADVANCEKNROL1012 Knurled 1.2–1.6...

  • Page 34: Periodic Maintenance

    BOC Smootharc Advance II MIG 250C Operating manual 12.0 Periodic Maintenance The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your MIG 250C welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables.

  • Page 35: Technical Specifications

    BOC Smootharc Advance II MIG 250C Operating manual 13.0 Technical Specifications Specifications MIG/MAG Part No. ADVANCE II 250C Power voltage Single phase 240 V ±15 % Frequency 50/60 Hz Rated input current (Ieff) Output current 50 A to 250 A...

  • Page 36: Warranty Information

    Warranty repairs may only be carried out by approved BOC service damage due to or resulting from natural wear and tear, non-compliance providers. Please contact your local BOC Gas & Gear for a directory of BOC with operating and maintenance instructions, connection to incorrect approved service providers in your area.
  • Page 37 BOC Smootharc Advance II MIG 250C Operating manual...
  • Page 38 BOC Smootharc Advance II MIG 250C Operating manual...
  • Page 40 970–988 Great South Road, Penrose, Auckland, New Zealand © BOC Limited 2015. BOC is a trading name of BOC Limited, a Member of The Linde Group. Reproduction without permission is strictly prohibited. Details given in this document are believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.

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