Linde BOC Smootharc TIG200 DC Operating Manual
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Linde BOC Smootharc TIG200 DC Operating Manual

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Summary of Contents for Linde BOC Smootharc TIG200 DC

  • Page 1 Smootharc TIG 200 DC Operating manual...
  • Page 2 BOC Smootharc TIG 200 DC Operating Manual Welcome to a better way of welding. This operating manual provides the basic knowledge required for TIG welding, as well as highlighting important areas of how to operate the Smootharc TIG 200 DC machine. With normal use and by following these recommended steps, your Smootharc TIG 200 DC machine can provide you with years of trouble free service.

  • Page 3: Table Of Contents

    BOC Smootharc TIG 200 DC Operating Manual Contents. 1.0 Recommended safety guidelines and precautions 5.0 Connections & Package contents Health hazard information 6.0 Control panel and display Personal protection Electrical shock Control Panel User responsibility Display Panel symbols Switch on to electrical safety 7.0 Smootharc TIG 200 DC installation Installation for TIG welding 2.0 Gas tungsten arc welding (GTAW/TIG)

  • Page 4: Recommended Safety Guidelines And Precautions

    BOC Smootharc TIG 200 DC 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 TIG 200 DC 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. such as stainless steel, nickel, nickel alloys or galvanised steel, further All appropriate safety equipment should be worn at all times, i.e.
  • Page 6 BOC Smootharc TIG 200 DC 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 Back-plug Before operating a cylinder valve Bursting disc...

  • Page 7: Electrical Shock

    BOC Smootharc TIG 200 DC 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: Switch On To Electrical Safety

    BOC Smootharc TIG 200 DC Operating Manual Switch on to electrical safety for single-phase equipment BOC welding machines are designed and manufactured to conform to IEC 60974 or AS 60974. This Standard not only covers the machine but also the input cable and plug requirements including the size of the plug that should be used.
  • Page 9 BOC Smootharc TIG 200 DC Operating Manual How important is the correct input cable and plug on a welding machine? The size of the plug depends on a formula that to understand input and output currents and to not only uses the maximum current draw but make sure that the input circuit is correctly rated ✓...

  • Page 10: Gas Tungsten Arc Welding (Gtaw/Tig)

    BOC Smootharc TIG 200 DC Operating Manual 2.0 Gas tungsten arc welding (GTAW/TIG) Introduction Schematic of the TIG welding process The Tungsten Inert Gas, or TIG process, uses the heat generated by an electric arc struck between a non-consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld pool.

  • Page 11: Shielding Gas Selection

    BOC Smootharc TIG 200 DC Operating Manual Shielding gas selection 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 Low fume Base material BOC Consumable Cobalt-based alloys Argon Stable and easy to control arc...

  • Page 12: Non Consumable Tungstens

    BOC Smootharc TIG 200 DC Operating Manual Non consumable tungstens Tungsten Electrode Selector Chart Welding Thickness range Desired results current Electrode type Shielding gas Tungsten performance characteristics Copper alloys, Cu-NI alloys and Nickel alloys General purpose DCSP 2% Thoriated 75% Argon/ Best stability at medium currents.
  • Page 13 BOC Smootharc TIG 200 DC 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 14: Welding Techniques

    BOC Smootharc TIG 200 DC Operating Manual Welding techniques Torch movement during welding TIG Welding techniques Tungsten Without Filler Rod Tungsten With Filler Rod 90° Welding direction Welding Vertical 75° direction 90° Welding Rod 70° 90° 60–75° Form pool Form pool 75°...

  • Page 15: Joint Preparation

    BOC Smootharc TIG 200 DC Operating Manual 2.10 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 0- S 6-20...
  • Page 16 BOC Smootharc TIG 200 DC 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 Tungsten inclusions Tungsten inclusions...

  • Page 17: Tig Welding Of Materials

    BOC Smootharc TIG 200 DC Operating Manual 3.0 TIG welding of materials Application summary C-Mn steel TIG welding may be used for welding carbon steel but because Material Type of current Polarity deposition rates are low, it is usually only used for welding sheet and thin sections for high quality applications, small components, and root C-Mn steel Direct current (-)

  • Page 18: Alloyed Steel

    BOC Smootharc TIG 200 DC Operating Manual Alloyed steel Stainless steel TIG welding may be used for welding alloy steels but because deposition TIG is a high quality process ideally suited for welding of stainless steels, rates are low, it is usually only used for welding sheet and thin sections particularly thin sheet up to about 5 mm thick where weld integrity for high quality applications, small components, and root passes of and good surface finish are critical.

  • Page 19: Copper And Copper Alloys

    BOC Smootharc TIG 200 DC Operating Manual Copper and copper alloys Copper and copper alloy welding parameters Cleanliness is important when welding copper, and all dirt, grease, and Plate thickness (mm) other contaminants must be removed before welding. Copper alloys Joint type Square butt Square butt...

  • Page 20: Manual Metal Arc Welding Process (Mmaw)

    BOC Smootharc TIG 200 DC Operating Manual 4.0 Manual Metal Arc Welding Process (MMAW) TIG Welding techniques Installation for MMA process Flux Covering Core Wire Weld Metal Slag Weld Pool Workpiece Process 4.2 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 21 BOC Smootharc TIG 200 DC Operating Manual 4.3 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 below. • selection of the correct electrode •...
  • Page 22 BOC Smootharc TIG 200 DC Operating Manual size. The following table gives the recommended maximum size of 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)
  • Page 23 BOC Smootharc TIG 200 DC Operating Manual Butt Welding FACE REINFORCEMENT WELD FACE ROOT FACE ROOT GAP 4.5 Types of Joints Correct Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same Butt Welds time the electrode is fed downwards to keep the correct arc length A butt weld is a weld made between two plates so as to give continuity...
  • Page 24 BOC Smootharc TIG 200 DC 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 25 BOC Smootharc TIG 200 DC 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 EFFECTIVE THROAT THEORETICAL THROAT...
  • Page 26 BOC Smootharc TIG 200 DC 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 27 BOC Smootharc TIG 200 DC Operating Manual Recommended Angles for Overhead Fillet Welds 45˚ 15˚ 30˚ Typical Defects Due to Faulty Technique has equal leg lengths and the contour of the completed fillet weld is slightly convex with no hollows in the face. Manual metal arc welding, like other welding processes, has welding Vertical fillet welds can be carried out using the upwards or downwards procedure problems that may develop which can cause defects in the...
  • Page 28 BOC Smootharc TIG 200 DC 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 29: Power

    BOC Smootharc TIG 200 DC Operating Manual 5.0 Connections & Package contents Power MMA operation The machine is designed to operate on a 240V ±15% input single phase The Smootharc TIG 200 DC can be used as an MMA welding machine by AC outlet.
  • Page 30 BOC Smootharc TIG 200 DC Operating Manual Front Connections of TIG 200 ACDC Back Connections of TIG 200 ACDC Welding cable quick socket (+) Power switch In TIG mode, connect with work piece; Use this switch to supply single phase 240V AC power for welding In MMA mode, connect with electrode holder.

  • Page 31: Control Panel And Display

    BOC Smootharc TIG 200 DC Operating Manual 6.0 Control panel and display Control Panel of TIG 200 ACDC Control Panel Icon Name Description Rotate the knob directly to set welding current. Adjustment knob With the “menu button”, rotate the knob to set pre-gas time, start current, up-slope time, etc. Welding mode button Used to switch the MMA and TIG mode MMA indicator...

  • Page 32: Display Panel Symbols

    BOC Smootharc TIG 200 DC Operating Manual Display Panel symbols Icon Name Description VRD indicator Under the MMA mode, open/close the VRD function by pressing and holding the “menu button”. The machine has HF and LIFT modes for TIG arc initiation: HF indicator HF mode –...

  • Page 33: Smootharc Tig 200 Dc Installation

    BOC Smootharc TIG 200 DC Operating Manual 7.0 Smootharc TIG 200 DC installation Installation for TIG setup Installation for TIG welding Plug the work return lead into output socket , and tighten firmly. Connect work return clamp to the work piece. Plug the 8-pin plug of TIG torch into the welding machine control socket.

  • Page 34: Starting Up

    BOC Smootharc TIG 200 DC Operating Manual 1. 2T (LIFT) mode IMPORTANT Before you begin a welding operation, please press the torch switch for a few seconds until all the air in the gas tube is removed. WARNING It is dangerous to connect or disconnect the gas hose or connector whilst welding.

  • Page 35: Adjusting Parameters

    BOC Smootharc TIG 200 DC Operating Manual 5. Pre-gas Time 6. Start Current 7. Up-slope Time 8. Down-slope Time Adjusting parameters Under the TIG mode, select the 2T (LIFT), 2T (HF), 4T (HF) or Spot (HF) mode first by pressing the welding menu button for 3 seconds. Select the parameters (Figures 5~14) to be set by pressing the welding menu button, and then adjusting the parameter value using the Adjustment Knob.

  • Page 36: Dc Current In Tig Welding

    BOC Smootharc TIG 200 DC Operating Manual GTAW with DCEN produces deep penetration because it concentrates the heat in the joint area. No cleaning action occurs with this. The heat generated by the arc using this polarity occurs in the work thus a smaller electrode can be used as well as a smaller gas cup and gas flow.

  • Page 37: Start Welding

    BOC Smootharc TIG 200 DC Operating Manual 9. Stop Current 10. Post-gas Time 11. Spot Welding Time 12. Pulse Frequency 13. Pulse Base Current 14. Pulse Width Start welding Begin welding in either HF or LIFT TIG mode. HF: Keep 2-4mm distance between the tungsten and the work piece. Press the torch switch to start welding.

  • Page 38: Tig Weld Initiation And Termination Stages

    BOC Smootharc TIG 200 DC Operating Manual TIG weld initiation and termination stages 2T (LIFT) mode 2T (HF) mode 4T (HF) mode Spot (HF) mode...

  • Page 39: Installation & Operation Mma Welding

    BOC Smootharc TIG 200 DC Operating Manual 8.0 Installation & Operation MMA welding Installation for MMA process Installation and Operation for MMA welding Plug the work return lead into output socket , and tighten firmly. Connect the work return clamp to the work piece. Plug the electrode holder cable into output socket , and tighten firmly.

  • Page 40: Operation For Mma Mode

    BOC Smootharc TIG 200 DC Operating Manual 15. MMA Mode with VRD 16. MMA Mode without VRD 17 Welding Current Figure 18 Hot Start Current 19 Hot Start Time 20 Arc Force Current Operation for MMA mode Adjusting parameters Under the MMA mode, select the parameters (Figures 17–20) by pressing Set welding mode the menu button, and then adjusting the parameter value using the Press the welding mode button on the front panel to choose MMA mode.

  • Page 41: Periodic Maintenance

    BOC Smootharc TIG 200 DC Operating Manual 9.0 Periodic maintenance WARNING Only authorised repair agents 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. The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your Smootharc welder.

  • Page 42: Troubleshooting And Fault Finding

    BOC Smootharc TIG 200 DC Operating Manual 10.0 Troubleshooting and fault finding IMPORTANT: Only authorised repair agents with valid certifications should carry out repairs and internal servicing. Troubleshooting Faults symptom Reasons Solutions 1 No display on panel 1 Not connected to the power supply 1 Make sure the input power supply is normal.

  • Page 43: Warranty Information

    BOC Smootharc TIG 200 DC Operating Manual 11.0 Warranty information 11.1 Terms of warranty 11.3 Warranty repairs BOC provides a warranty for the Smootharc TIG 200 DC machine sold BOC or their Authorised Service Agent must be informed of the warranty against defects in manufacture and materials.

  • Page 44: Technical Specifications

    BOC Smootharc TIG 200 DC Operating Manual 12.0 Technical specifications Specifications Smootharc TIG 200 DC Part No. BOCTIG200DC Input voltage Single phase AC 240V ±15% Frequency 50/60 Hz Maximum rated input current (I 27 A 28 A 1max Maximum effective supply current (I 13.5 A 14 A 1eff...
  • Page 45 BOC Smootharc TIG 200 DC Operating Manual...
  • Page 46 BOC Smootharc TIG 200 DC Operating Manual...
  • Page 48 © BOC Limited 2019. 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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