Linde BOC Smootharc Advance II MIG 400R Operating Manual
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Linde BOC Smootharc Advance II MIG 400R Operating Manual

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Summary of Contents for Linde BOC Smootharc Advance II MIG 400R

  • Page 1 MIG 400R Operating manual...
  • Page 2 BOC Smootharc Advance II MIG 400R Operating manual Welcome to a better way of welding. This operating manual provides the basic knowledge required for MIG Welding, as well as highlighting important areas of how to operate your Smootharc Advance machine.

  • Page 3: Table Of Contents

    BOC Smootharc Advance II MIG 400R Operating manual Contents. Recommended Safety Guidelines and Precautions Health hazard information 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 400R 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 400R 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, further hazards.

  • Page 6: Electrical Shock

    BOC Smootharc Advance II MIG 400R 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 400R 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 400R 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 400R Operating manual Process Schematic Diagram for MIG / 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 efficiency varies differs by wire type and manufacturer it is typically between 75–85%.
  • Page 10 BOC Smootharc Advance II MIG 400R 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 filled entirely with metal powder except for a small amount of non- The most common modes of transfer in FCAW are: metallic compounds.
  • Page 11 BOC Smootharc Advance II MIG 400R Operating manual Schematic of Globular Transfer Schematic of Spray Transfer Gas shroud Shielding gas Wire Droplets Weld Splatter Large droplet Workpiece Workpiece argon-based gases, the drops are not as large and are transferred in The current flows continuously because of the high voltage maintaining a more axial direction.

  • Page 12: Fundamentals Of Mig, Fcaw And Mcaw

    BOC Smootharc Advance II MIG 400R Operating manual Typical metal transfer mode Cast and helix Globular Spray Transfer Transfer Transfer Process Cast Metal Inert Gas � � � (MIG) Helix Flux Cored � � �* Cast – Diameter of the circle (Gas Shielded) Helix –...
  • Page 13 BOC Smootharc Advance II MIG 400R 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

    BOC Smootharc Advance II MIG 400R Operating manual 3.0 MMA Process Schematic of MMA process in operation Process 3.2 Welding machine Manual Metal Arc welding is the process of joining metals where an The most important consideration when contemplating the use of arc electric arc is struck between the metal to be welded (parent metal) and welding for the first time is the purchase of a suitable welding machine.

  • Page 15: Welding Technique

    BOC Smootharc Advance II MIG 400R Operating manual 3.3 Welding technique appeals to the beginner and experienced operator alike. For further recommendations on the selection of electrodes for specific applications, Successful welding depends on the following factors: see table on the next page.
  • Page 16 BOC Smootharc Advance II MIG 400R Operating manual Electrode size In the case of welding machines with separate terminals for different size electrodes, ensure that the welding lead is connected to the correct The size of the electrode is generally dependent on the thickness of the terminal for the size electrode being used.

  • Page 17: Types Of Joints

    BOC Smootharc Advance II MIG 400R 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 18 BOC Smootharc Advance II MIG 400R Operating manual Welding Progression Angle General notes on Butt Welds Double ‘V’ Butt Weld The first run in a prepared butt weld should be deposited with an Used on plate of 12 mm and over in thickness when welding can be applied from both sides.

  • Page 19: Fillet Welds

    BOC Smootharc Advance II MIG 400R 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 20 BOC Smootharc Advance II MIG 400R Operating manual Recommended Electrode Angles for Fillet Welds Recommended Angles for Overhead Fillet Welds 1st Run 2nd Run 55–60° 55–60° 55–60° 55–60° 40° 40° 40° 40° 3rd Run Multi-run Fillet 45˚ 15˚ 30˚ 20–30°...

  • Page 21: Typical Defects Due To Faulty Technique

    BOC Smootharc Advance II MIG 400R Operating manual Slag Inclusions Undercutting Lack of Fusion Correct selection of electrodes is important for vertical welding. → too large an electrode being used → letting slag run ahead of the arc. In overhead fillet welds, careful attention to technique is necessary to This defect can be prevented by: obtain a sound weld of good profile.
  • Page 22 BOC Smootharc Advance II MIG 400R Operating manual Lack of Fusion Lack of fusion is when the weld metal is not fused to the base metal. This can occur between the weld metal and the base metal or between passes in a multiple pass weld. Causes of this defect can be: →...

  • Page 23: General Welding Information

    BOC Smootharc Advance II MIG 400R Operating manual 4.0 General Welding Information Recommended Welding Parameters Argoshield Light Indicative Welding Parameters Dip Transfer Spray Transfer Material thickness (mm) 1–1.6 8–9 Welding position Horizontal / Horizontal / Horizontal / Horizontal / Horizontal Horizontal...
  • Page 24 BOC Smootharc Advance II MIG 400R Operating manual Argoshield Heavy Indicative Welding Parameters Dip Transfer Spray Transfer Material thickness (mm) Horizontal/ Horizontal/ Horizontal Horizontal Welding position Vertical Vertical Wire diameter (mm) 140–160 140–160 240–260 290–330 Current (amps) 17–18 17–18 27–29 28–31 Voltage (volts) 3.2–4.0...

  • Page 25: Correct Application Techniques

    BOC Smootharc Advance II MIG 400R 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 Torch positioned at a drag angle of 10° narrow bead with excessive reinforcement.
  • Page 26 BOC Smootharc Advance II MIG 400R 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 27: Package Contents

    BOC Smootharc Advance II MIG 400R Operating manual 6.0 Package contents Smootharc Advance II MIG 400R Power source with input cable MIG Torch Binzel ABIMIG 455 BOC Argon regulator Work return lead Electrode holder Wire feeder 1.5m & 10m inter-connecting cable 1.5 m &...

  • Page 28: Installation

    BOC Smootharc Advance II MIG 400R Operating manual 7.0 Installation Installation for MIG/MAG process Installation for MIG/MAG process Primary current rating This machines has a maximum primary current input (I ) rating of 1max 26.5 amps. To obtain full rated output, they must be: 1 Connect the gas cylinder to the regulator.
  • Page 29 BOC Smootharc Advance II MIG 400R Operating manual MIG/MAG solid wire polarity setting For solid wire (DCEP). • Connect the inter-connection cable to the wire feed control and power sockets at the rear of the power source. Repeat this on the wire feeder.

  • Page 30: Installation For Mma Process

    BOC Smootharc Advance II MIG 400R Operating manual Installation for MMA process Installation for MMA process 1 Connect the electrode holder to the positive (+) of the machine and fasten it clockwise tightly. 2 Connect the work return lead into the negative (-) of the machine and fasten it clockwise.

  • Page 31: Operation Setup

    BOC Smootharc Advance II MIG 400R Operating manual 8.0 Operation Setup Front and back of power source Front and back of wire feeder Current/wire speed adjustment Wire feeder mechanical connection Shielding gas connection Power Inductance adjustment Voltage meter Cable connection (14 pin control)

  • Page 32: Control Panels

    BOC Smootharc Advance II MIG 400R Operating manual 9.0 Control panels Control panel of MIG 400R Control panel of wire feeder On/Off switch Wire inch button Power Current meter Thermal protection/fault indicator Voltage meter 2T/4T button Wire diameter selection Process selection switch...

  • Page 33: 2T Trigger Latch Selection

    BOC Smootharc Advance II MIG 400R Operating manual rapidly and burn off the wire violently. This rapid melt flings about metal has to hold the trigger down for long periods of time and may cause globules as it takes place. These globules settle on the work-piece and discomfort.

  • Page 34: Troubleshooting And Fault Finding

    BOC Smootharc Advance II MIG 400R 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 35: Replacement Parts

    BOC Smootharc Advance II MIG 400R Operating manual 11.0 Replacement Parts Suitability Description Part No. Torch Binzel ABIMIG 455 4 m 015.D074.1 Wire Feed Rollers Self-Shielded Flux Cored Knurled 0.8-0.9 ADVANCE KN ROL 0809 Knurled 1.0-1.2 ADVANCE KN ROL 1012 Knurled 1.2-1.6...

  • Page 36: Periodic Maintenance

    BOC Smootharc Advance II MIG 400R 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 Smootharc Advance welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables.

  • Page 37: Technical Specifications

    BOC Smootharc Advance II MIG 400R Operating manual 13.0 Technical specifications Specifications MIG/MAG Part No. ADVANCE II400R Input voltage Three phase 420 V ±15 % Frequency 50/60 Hz No load voltage 66 V 25 A 26.5 A Maximum rated input current (I...

  • Page 38: Warranty Information

    BOC Smootharc Advance II MIG 400R Operating manual 14.0 Warranty Information 14.1 Terms of Warranty 14.3 Warranty Period The Smootharc Advance machine has a limited warranty that covers The warranty is valid for 3 years from date of purchase provided the manufacturing and material defects only.
  • Page 39 BOC Smootharc Advance II MIG 400R Operating manual...
  • Page 40 © BOC Limited 2017. 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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