Smootharc 180 Multiprocess Operating Manual
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Smootharc 180 Multiprocess Operating Manual

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180 Multiprocess
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  • Page 1 180 Multiprocess Operating manual...
  • Page 2 Smootharc 180 Multiprocess machine. With normal use and by following these recommended steps, your Smootharc 180 Multiprocess machine can provide you with years of trouble-free service. Smootharc equipment and technical support is available through the national BOC Customer Service Centre or contact your local Gas &...

  • Page 3: Table Of Contents

    BOC Smootharc 180 Multiprocess operating manual 1.0 Recommended Safety Guidelines and Precautions Health Hazard Information Personal Protection Electrical shock User Responsibility Contents. 2.0 MIG/MAG Operating Manual Introduction to Metal Inert Gas (MIG) & Metal Active Gas (MAG) Introduction to Flux Cored Arc Welding (FCAW)

  • Page 4: Recommended Safety Guidelines And Precautions

    BOC Smootharc 180 Multiprocess 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 180 Multiprocess 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 welding is one that can cause a variety of hazards.
  • Page 6 BOC Smootharc 180 Multiprocess operating manual Back view of typical cylinder valve. Operator wearing personal protective equipment (PPE) in safe position. When moving cylinders, ensure that the valve is not accidentally opened Cylinder safety diagram in transit. Cylinder valve hand-wheel...

  • Page 7: Electrical Shock

    BOC Smootharc 180 Multiprocess 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 8: Mig/Mag Operating Manual

    BOC Smootharc 180 Multiprocess operating manual 2.0 MIG/MAG Operating Manual Typical MIG/MAG set up Torch Torch trigger Shroud Gas diffuser Contact tip Welding wire Shielding Weld Droplets Weld pool Introduction to Metal Inert Gas (MIG) • Argon with oxygen mixtures (MAG) &...
  • Page 9 BOC Smootharc 180 Multiprocess operating manual Extended self shielded flux cored wire nozzle The wire feed unit takes the filler wire from a spool, and feeds it cored wire is much smaller than that of a solid MIG/MAG wire. This...

  • Page 10: Introduction To Metal Cored Arc Welding (Mcaw)

    BOC Smootharc 180 Multiprocess operating manual Process Schematic Diagram for MIG/MAG, FCAW and MCAW Gas hose Continuous 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 nitrogen and hydrogen into the weld pool, which can affect the quality of the weld.

  • Page 11: Modes Of Metal Transfer

    BOC Smootharc 180 Multiprocess 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/MAG, which uses a solid consumable filler wire, the...
  • Page 12 BOC Smootharc 180 Multiprocess 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 Metal transfer is controlled by slow ejection resulting in large, because of its low density and high thermal conductivity, spray transfer irregularly-shaped ‘globs’...

  • Page 13: Fundamentals Of Mig/Mag, Fcaw And Mcaw

    BOC Smootharc 180 Multiprocess operating manual Typical Metal Transfer Mode Globular Spray Transfer Transfer Transfer Process Metal Inert Gas (MIG) � � � Metal Active Gas (MAG) � � �* Flux Cored (Gas Shielded) � � � Flux Cored (Self Shielded) Metal Cored �...
  • Page 14 BOC Smootharc 180 Multiprocess operating manual Cast and Helix Cast Helix Cast – Diameter of the circle Helix – Vertical height black residue is found on the cloth the surface of the wire is not properly Selection of the Correct Polarity on the Power Source cleaned.

  • Page 15: 2T Trigger Latch Selection

    BOC Smootharc 180 Multiprocess operating manual More detailed selection charts, including recommendations for welding parameters (voltage, amperage, electrical stickout, travelspeed and gasflow rate) can be found in the following pages. 2.6 4T/2T Trigger Latch Selection On all MIG machines there is no current or wire feed until the trigger on the torch is depressed.

  • Page 16: Gas Tungsten Arc Welding (Gtaw/Tig)

    BOC Smootharc 180 Multiprocess operating manual 3.0 Gas tungsten arc welding (GTAW/TIG) Schematic of the TIG welding process Collet Shielding gas Tungsten electrode TIG filler rod Weld pool Workpiece Introduction The Tungsten Inert Gas, or TIG process, uses the heat generated by an...

  • Page 17: Process Variables

    BOC Smootharc 180 Multiprocess operating manual 3.3 Process variables Process variable Explanation Usage DCEN When direct-current electrode-negative (straight polarity) For a given diameter of tungsten electrode, higher Narrow bead, is used: amperage can be used with straight polarity. Straight deep penetration polarity is used mainly for welding: •...

  • Page 18: Shielding Gas Selection

    BOC Smootharc 180 Multiprocess operating manual Shielding gas selection 3.5 Welding wire selection The following table includes the recommended welding consumable for Material Shielding gas Benefits the most commonly welded materials. Brass Argon Stable arc Base material BOC Consumable Low fume...

  • Page 19: Tungsten Electrode Selection

    BOC Smootharc 180 Multiprocess operating manual Tungsten electrode selection Thickness Welding Base metal type range Desired results current Electrode type Shielding gas Tungsten performance characteristics Copper alloys, General purpose DCSP 2% Thoriated 75% Argon/ Best stability at medium currents. Good arc...
  • Page 20 BOC Smootharc 180 Multiprocess operating manual Tungsten electrode tip shapes and current ranges Tungsten tip preparation Thoriated, ceriated, and lanthanated tungsten electrodes do not ball DCSP (EN) or DCRP (EP) ACHP General Purpose as readily as pure or zirconiated tungsten electrodes, and as such are typically used for DCSP welding.

  • Page 21: Welding Techniques

    BOC Smootharc 180 Multiprocess operating manual Welding techniques 3.8 Torch movement during welding TIG Welding techniques Tungsten Without Filler Rod Tungsten With Filler Rod Welding direction Welding Vertical 75° direction Welding Rod 60–75° Form pool Form pool 75° Shield gas Nozzle 15–30°...

  • Page 22: Positioning Torch Tungsten For Various Weld Joints

    90° BOC Smootharc 180 Multiprocess operating manual 90° 70° 90° 70° 90° 20° 70° 90° 20° 20° 20° 20° 20° 20° 20° 75° 10° 75° 20° 75° 10° 15° 75° 15° 10° 15° 10° 15° 10° 70° 90° 10° 70°...

  • Page 23: Joint Preparation

    BOC Smootharc 180 Multiprocess operating manual 3.10 Joint preparation 10° 10° 10° 6-20 6-20 6-20 10° 10° 10° 1.5-3 6-20 0- S 1.5-3 1.5-3 6-20 6-20 0- S 0- S 10° 10° 10° 6-20 1.5-3 1.5-3 1.5-3 0- S 0- S...
  • Page 24 BOC Smootharc 180 Multiprocess operating manual Condition Result Long arc length Undercut Porosity Wide bead profile Loss of gas Acute angle coverage Oxides Unsymmetrical bead Angular profile mis-alignment Incomplete Mis-alignment penetration Filler rod removed from gas shield Oxides Oxides movement...

  • Page 25: Manual Metal Arc Welding Process (Mmaw)

    • or infinitely variable control. reversal is called a ‘half cycle’ and repeats as long as the current For example, the Smootharc 175 Multiprocess connects to 240 Volt flows. The rate of change of direction of current flow is known as the supply (15 amps Input), has an output of 175 amps DC @ 35% duty ‘frequency’...

  • Page 26: Welding Technique

    For general mild steel work, however, BOC Smootharc 13 electrodes Electrode Size will handle virtually all applications. BOC Smootharc 13 is suitable for The size of the electrode is generally dependent on the thickness of the welding mild steel in all positions using AC or DC power sources. Its easy-...
  • Page 27 The following table shows the current ranges generally recommended electrodes that may be used for various thicknesses of section. for BOC Smootharc 13. Generally Recommended Current Range for BOC Smootharc 13 Recommended Electrode Sizes Size of Electrode (mm) Current Range (Amp) Average Thickness of Plate or Section Max.

  • Page 28: Types Of Joints

    • Root Gap: the separation between root Run Length per Electrode – BOC Smootharc 13 faces of the parts to be joined. Run Length (mm) Various types of butt welds are in common use and their suitability for Electrode Size (mm) Electrode Length (mm) Min.
  • Page 29 BOC Smootharc 180 Multiprocess operating manual Welding Progression Angle Electrode 70–85˚ Weld Metal Slag Weld Pool Workpiece Direction of Welding All single ‘V’, single ‘U’ and square butt welds should have a backing Butt Weld with Backing Material run deposited on the underside of the joint; otherwise 50% may be When square butt welds or single ‘V’...

  • Page 30: Fillet Welds

    BOC Smootharc 180 Multiprocess operating manual Convex Fillet Weld Concave Fillet Weld CONVEXITY ACTUAL THROAT CONVEXITY ACTUAL THROAT SIZE CONCAVITY SIZE LENGH CONCAVITY ACTUAL THROAT LENGH AND EFFECTIVE ACTUAL THROAT SIZE LEG THROAT AND EFFECTIVE EFFECTIVE THROAT SIZE LEG THROAT...
  • Page 31 BOC Smootharc 180 Multiprocess operating manual specified leg length has a throat thickness in excess of the effective Selection of welding current is important. If it is too high the weld measurement. surface will be flattened, and undercut accompanied by excessive spatter is likely to occur.

  • Page 32: Typical Defects Due To Faulty Technique

    Defects that can occur and smooth (only BOC Smootharc 13 is suitable for this position). when using the shielded metal arc welding process are slag inclusions,...
  • Page 33 BOC Smootharc 180 Multiprocess operating manual 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. • a uniform travel speed •...

  • Page 34: General Welding Information

    BOC Smootharc 180 Multiprocess operating manual 5.0 General Welding Information Recommended Welding Parameters for MIG/MAG Argoshield Light Indicative Spray Welding Parameters Dip Transfer Transfer Material thickness (mm) 1–1.6 Welding position Horizontal / Horizontal / Horizontal / Horizontal / Horizontal Vertical Vertical...

  • Page 35: Correct Application Techniques

    BOC Smootharc 180 Multiprocess operating manual 6.0 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 36 BOC Smootharc 180 Multiprocess operating manual Electrical stickout Travel speed Short Normal Long Slow Normal Fast Slow Normal Fast Short Normal Long Torch position for fillet welds When welding fillet welds the torch should be positioned at an angle of 45°...

  • Page 37: Package Contents

    BOC Smootharc 180 Multiprocess operating manual 7.0 Package Contents Package consists of the following: • Power source • Work return lead • Electrode holder with cable • Lift-TIG 26 torch • Binzel MB15AK MIG/MAG torch • Regulator • Gas hose •...

  • Page 38: Installation

    BOC Smootharc 180 Multiprocess operating manual 8.0 Installation Installation for MIG/MAG process Installation for MIG/MAG set up with OPTIONAL spool gun Optional spool gun purchased separately (not part of this package) WARNING Ensure that all power to machine is turned off...

  • Page 39: Installation For Tig Setup

    BOC Smootharc 180 Multiprocess operating manual Installation for TIG setup Installation for MMA process 8.3 Installation for TIG setup 8.4 Installation for MMA process 1 Connect the gas cylinder to the regulator. Connect MIG gas hose to 1 Connect the...

  • Page 40: Control Panels

    BOC Smootharc 180 Multiprocess operating manual 9.0 Control panels Front panel of 180 Multiprocess Multifunctional data display MMA indicator Lift TIG indicator MIG indicator MIG Pulse Al indicator MMA/Lift TIG/MIG/MIG Pulse Al Data selection Multifunctional data adjustment Spool gun indicator Multifunctional parameter adjustment •...

  • Page 41: Operation

    BOC Smootharc 180 Multiprocess operating manual 10.0 Operation Illustration 1. Start-up display 10.1 Starting up Switch on the machine. The Multifunctional data display will flash for 5 seconds. The panel will display the previous settings that were saved in the last shutdown.
  • Page 42 BOC Smootharc 180 Multiprocess operating manual Illustration 5. MIG mode – Current preset Data Selection Key twice. The Multifunctional Data Press the Display is shown as Illustration 5, this allows inductance adjustment in the range of ±10% Multifunctional Data Without any operation after 5 seconds, the Display will revert back to the default setting.

  • Page 43: Operation Instruction Under Lift Tig Mode

    BOC Smootharc 180 Multiprocess operating manual Illustration 9. LIFT TIG Mode Illustration 10. LIFT TIG Mode Illustration 11. MMA Mode with VRD Enabled 10.3 Operation instruction under LIFT TIG mode. Press the Function Switch Key to LIFT TIG mode. The LIFT TIG indicator light will illuminate (Illustration 9).

  • Page 44: Error Display

    BOC Smootharc 180 Multiprocess operating manual Illustration 13. Error Display of Wire Feeder Illustration 14. Error display of over current Illustration 15. Error display of overheating protection 10.5 Error display Error display of wire feeder The panel displays as Illustration 13 when the wire feeder is malfunctioning.
  • Page 45 BOC Smootharc 180 Multiprocess operating manual...

  • Page 46: Troubleshooting And Fault Finding

    BOC Smootharc 180 Multiprocess operating manual 11.0 Troubleshooting and Fault Finding 11.1 TIG/MMA functions Excessive electrode consumption Cause Solution Inadequate gas flow Increase gas flow Inadequate post gas flow Increase post flow time to 1 sec per 10 amps Improper size electrode for current required...
  • Page 47 BOC Smootharc 180 Multiprocess operating manual Cracking in Welds Cause Solution Hot cracking in heavy sections or welding on metals prone Increase weld bead cross-section size. Change weld bead contour for e.g. concave to flat or to hot cracking convex, check fit-up gap, reduce welding speed Post weld cold cracking due to excessive joint restraint, Preheat prior to welding.

  • Page 48: Mig/Mag Functions

    BOC Smootharc 180 Multiprocess operating manual 11.2 MIG/MAG functions Power source Component Fault symptom Cause Primary cable No or low welding output Poor or incorrect primary connection, lost phase Earth cable and clamp Arc will not initiate Damaged, loose or undersized cables and clamps Connectors and lugs Overheating of connectors and lugs...
  • Page 49 BOC Smootharc 180 Multiprocess operating manual Porosity in Weld Deposit Cause Solution Entrapped impurities, hydrogen, air, nitrogen, water Do not weld on wet material. vapour Defective gas hose or loose connection Check hoses and connections for leaks Filler material is damp (particularly aluminium)

  • Page 50: Periodic Maintenance

    BOC Smootharc 180 Multiprocess operating manual 12.0 Periodic Maintenance WARNING Only authorised electricians should carry out repairs and internal servicing. Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void.

  • Page 51: Technical Specifications

    BOC Smootharc 180 Multiprocess operating manual 13.0 Technical Specifications Specifications 180 Multiprocess Part No. BOC180MULTI Input voltage Single phase 240 V ±15 % Frequency 50/60 Hz 31.2 A 24 A 31.1 A Maximum rated input current (I 1max 14 A 12 A 13.9 A...

  • Page 52: Warranty Information

    14.1 Terms of Warranty 14.3 Warranty Period The Smootharc machine has a limited warranty that covers The warranty is valid for 18 months from date of purchase provided the manufacturing and material defects only. The warranty is affected on the machine is used within the published specification limits.
  • Page 56 For more information contact the BOC Customer Engagement Centre on 131 262 (AU) or 0800 111 333 (NZ) BOC Limited ABN 95 000 029 729 10 Julius Avenue, North Ryde NSW 2113, Australia www.boc.com.au BOC Limited WN007748 970–988 Great South Road, Penrose, Auckland, New Zealand www.boc.co.nz ©...

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