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Linde BOC Smootharc TIG 200 ACDC Operating Manual

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Smootharc TIG 200 ACDC
Operating manual

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Summary of Contents for Linde BOC Smootharc TIG 200 ACDC

  • Page 1 Smootharc TIG 200 ACDC Operating manual...
  • Page 2 BOC Smootharc TIG 200 ACDC 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 ACDC machine.

  • Page 3: Table Of Contents

    BOC Smootharc TIG 200 ACDC Operating Manual Contents. 1.0 Recommended safety guidelines and precautions 4 12.0 Troubleshooting and fault finding Health hazard information 13.0 Periodic maintenance Personal protection Electrical shock 13.1 Power source User responsibility 14.0 Warranty information 14.1 Terms of warranty Switch on to electrical safety 14.2 Limitations on warranty...

  • Page 4: Recommended Safety Guidelines And Precautions

    BOC Smootharc TIG 200 ACDC 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 ACDC Operating Manual • Fumes from the welding of some metals could have an adverse effect  Health hazard information 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 ACDC 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 TIG 200 ACDC 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 throughout the South Pacific. • Never touch ‘live’ electrical parts • Always repair or replace worn or damaged parts •...

  • Page 8: Switch On To Electrical Safety

    BOC Smootharc TIG 200 ACDC 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 ACDC 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: Package Contents

    BOC Smootharc TIG 200 ACDC Operating Manual 2.0 Package contents Package Contents Power source Work return lead TIG torch Regulator Gas hose Operator’s manual Optional Accessories Part No. Foot control 340050-00018...

  • Page 11: Technical Specifications

    BOC Smootharc TIG 200 ACDC Operating Manual 3.0 Technical specifications Specifications Part No. BOCTIG200ACDC Rated input voltage Single phase, AC230V +15%/-20% Frequency 50/60Hz Rated input power 5.7 Kw Rated max. input current 25 A Rated efficient input current 14 A Open load voltage 60 V 13.2 V (VRD)

  • Page 12: Connections

    BOC Smootharc TIG 200 ACDC Operating Manual 4.0 Connections Front Connections of TIG 200 ACDC Back Connections of TIG 200 ACDC % Hz VRD Arc Force Selection Adjustment TIG 200 ACDC Welding cable quick socket (+) Power switch In TIG mode, connect with work piece;...

  • Page 13: Smootharc Tig 200 Acdc Installation

    BOC Smootharc TIG 200 ACDC Operating Manual 5.0 Smootharc TIG 200 ACDC installation Installation for TIG setup Installation for TIG setup using foot control Foot pedal Installation for TIG welding Optional Foot Pedal Foot pedal switch can be used for arc start control and welding , and tighten firmly.

  • Page 14: Control Panel

    BOC Smootharc TIG 200 ACDC Operating Manual 6.0 Control panel Control Panel of TIG 200 ACDC Function switches AC/DC selection button: select between AC, DC, mixed waveform on TIG mode. Select between AC, DC on MMA mode. IMPORTANT! When both AC and DC lights are ON this means the machine is on mixed waveform TIG mode.

  • Page 15: Operation For Tig Welding

    BOC Smootharc TIG 200 ACDC Operating Manual 7.0 Operation for TIG welding Control panel Gas Regulator Open Adjust TIG welding parameters Operation for TIG welding 1 Press the bottom left button to select function: HF TIG, Lift TIG, MMA. 2 Press the top left button to select...

  • Page 16: Operation For Ac Tig Welding

    BOC Smootharc TIG 200 ACDC Operating Manual 8.0 Operation for AC TIG welding 1. Select TIG function % Hz VRD Function Arc Force Selection Adjustment TIG 200 ACDC 1 Press the bottom left button to select function: HF TIG, Lift TIG 2.
  • Page 17 BOC Smootharc TIG 200 ACDC Operating Manual 8. Select Current 9. Adjust Current % Hz VRD % Hz VRD Arc Force Arc Force Selection Adjustment Selection Adjustment TIG 200 ACDC TIG 200 ACDC 8 Rotate the left knob to select “Current”...

  • Page 18: Operation For Dc Pulse Tig Welding

    BOC Smootharc TIG 200 ACDC Operating Manual 9.0 Operation for DC Pulse TIG welding 1. Select TIG function 2. Select DC welding mode Welding mode % Hz VRD % Hz VRD Function Arc Force Arc Force Selection Adjustment Selection Adjustment...
  • Page 19 BOC Smootharc TIG 200 ACDC Operating Manual 9. Select Current 10. Adjust Current % Hz VRD % Hz VRD Arc Force Arc Force Selection Adjustment Selection Adjustment TIG 200 ACDC TIG 200 ACDC 9 Rotate the left knob to select “Current”...

  • Page 20: Tig Torch Operation Mode

    BOC Smootharc TIG 200 ACDC Operating Manual 10.0 TIG Torch Operation Mode 10.1 2T operation mode (HF TIG) TIG torch operation modes Press and hold torch trigger to start welding - Open solenoid valve. Shielding gas will flow out to expel air from  torch hose (pre-gas time depends on the hose length). Then HF ignition device works and arc starts.

  • Page 21: Installation & Operation For Mma Use

    BOC Smootharc TIG 200 ACDC Operating Manual 11.0 Installation & Operation for MMA use Installation for MMA process Control panel use in MMA function Welding mode % Hz VRD Function Arc Force Selection Adjustment TIG 200 ACDC Adjustable welding parameters in MMA DC mode...

  • Page 22: Troubleshooting And Fault Finding

    BOC Smootharc TIG 200 ACDC Operating Manual 12.0 Troubleshooting and fault finding   O nly authorised repair agents with valid certifications should carry out repairs and internal servicing.  IMPORTANT: Troubleshooting Trouble Causes Remedy Indicator lights of display board do not light 1. Power switch is damaged 1. Check power switch up. Fan does not run. No output when machine 2.

  • Page 23: Periodic Maintenance

    BOC Smootharc TIG 200 ACDC Operating Manual 13.0 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.

  • Page 24: Warranty Information

    BOC Smootharc TIG 200 ACDC Operating Manual 14.0 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 ...

  • Page 25: Gas Tungsten Arc Welding (Gtaw/Tig)

    BOC Smootharc TIG 200 ACDC Operating Manual 15.0 Gas tungsten arc welding (GTAW/TIG) Schematic of the TIG welding process Collet Shielding gas Tungsten electrode TIG filler rod Weld pool Workpiece 15.1 Introduction The Tungsten Inert Gas, or TIG process, uses the heat generated by an...

  • Page 26: Process Variables

    BOC Smootharc TIG 200 ACDC Operating Manual 15.3 Process variables Usage Process variable Explanation DCEN Narrow bead, When direct-current electrode-negative (straight polarity) For a given diameter of tungsten electrode, higher deep penetration is used: amperage can be used with straight polarity. Straight polarity is used mainly for welding: •...

  • Page 27: Shielding Gas Selection

    BOC Smootharc TIG 200 ACDC Operating Manual 15.4 Shielding gas selection 15.5 Welding wire selection The following table includes the recommended welding consumable for Benefits Material Shielding gas the most commonly welded materials. Aluminium Alloys Argon Used with high frequency AC good stable arc...

  • Page 28: Non Consumable Tungstens

    BOC Smootharc TIG 200 ACDC Operating Manual 15.6 Non consumable tungstens Tungsten Electrode Selector Chart Welding Thickness range Desired results current Electrode type Shielding gas Tungsten performance characteristics Aluminium alloys and Magnesium alloys General purpose ACHF Pure Argon Balls easily. Low cost. Tends to spit at higher currents. Used for non- (EW-P) critical welds only.

  • Page 29: Welding Techniques

    BOC Smootharc TIG 200 ACDC Operating Manual 15.7 Welding techniques 15.8 Torch movement during welding TIG Welding techniques Tungsten Without Filler Rod Tungsten With Filler Rod Welding direction Welding Vertical direction Welding Rod 60–75° Form pool Form pool Shield gas Nozzle 15–30°...
  • Page 30 BOC Smootharc TIG 200 ACDC 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...

  • Page 31: Positioning Torch Tungsten For Various Weld Joints

    BOC Smootharc TIG 200 ACDC Operating Manual 15.9 Positioning torch tungsten for various weld joints Butt Weld and Stringer bead Corner Joint 70° 90° 90° 75° 20° 15° ‘T’ Joint Lap Joint 20-40° 20° 75° 75° 15° 15° 10° 30°...

  • Page 32: Joint Preparation

    BOC Smootharc TIG 200 ACDC Operating Manual 15.10 Joint preparation 10° 6-20 0- S 1.5-3 50° 10° 50° 8-40 3-20 60° 1.5-3 2-3.5 15° 20° 50° Offset 15-40 Roll direction All measurements in mm...
  • Page 33 BOC Smootharc TIG 200 ACDC Operating Manual Condition Result Undercut Long arc length 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...

  • Page 34: Tig Welding Of Materials

    BOC Smootharc TIG 200 ACDC Operating Manual 16.0 TIG welding of materials 16.1 Application summary 16.2 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...

  • Page 35: Alloyed Steel

    BOC Smootharc TIG 200 ACDC Operating Manual 16.3 Alloyed steel 16.4 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 and good surface finish are critical. The process has a high degree of ...

  • Page 36: Aluminium

    BOC Smootharc TIG 200 ACDC Operating Manual 16.5 Aluminium 16.6 Balanced squarewave TIG is a high quality process widely used for welding aluminium, The balance on squarewave machines can be adjusted to achieve particularly in section size up to about 6mm. The process may be the desired results.

  • Page 37: Copper And Copper Alloys

    BOC Smootharc TIG 200 ACDC Operating Manual 16.7 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...

  • Page 38: Manual Metal Arc Welding Process (Mmaw)

    BOC Smootharc TIG 200 ACDC Operating Manual 17.0 Manual Metal Arc Welding Process (MMAW) TIG Welding techniques Installation for MMA process Flux Covering Core Wire Weld Metal Slag Weld Pool Workpiece 17.1 Process 17.2 Welding Machine Manual Metal Arc welding is the process of joining metals where an The most important consideration when contemplating the use of arc welding for the first time is the purchase of a suitable welding machine. ...
  • Page 39 BOC Smootharc TIG 200 ACDC Operating Manual 17.3 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 page 27.  • selection of the correct electrode •   s election of the correct size of the electrode for the job  Electrodes and Typical Applications • correct welding current Name AWS Class.
  • Page 40 BOC Smootharc TIG 200 ACDC Operating Manual size. The following table gives the recommended maximum size of The following table shows the current ranges generally recommended for BOC Smootharc 13.  electrodes that may be used for various thicknesses of section. Generally Recommended Current Range for BOC Smootharc 13...
  • Page 41 BOC Smootharc TIG 200 ACDC Operating Manual Butt Welding FACE REINFORCEMENT WELD FACE ROOT FACE ROOT GAP Correct Travel Speed 17.5 Types of Joints 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...
  • Page 42 BOC Smootharc TIG 200 ACDC 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 43 BOC Smootharc TIG 200 ACDC Operating Manual Convex Fillet Weld Concave Fillet Weld CONVEXITY ACTUAL THROAT SIZE LENGH CONCAVITY ACTUAL THROAT AND EFFECTIVE EFFECTIVE THROAT SIZE LEG THROAT THEORETICAL THROAT THEORETICAL THROAT 17.6 Fillet Welds Corner Joints The members are fitted as shown, leaving a ‘V’- A fillet weld is approximately triangular in section, joining two surfaces  shaped groove in which a fillet weld is deposited. ...
  • Page 44 BOC Smootharc TIG 200 ACDC 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 surface will be flattened, and undercut accompanied by excessive  measurement. spatter is likely to occur. Alternatively, a current which is too low will Concave Fillet Weld produce a rounded narrow bead with poor penetration at the root.
  • Page 45 BOC Smootharc TIG 200 ACDC Operating Manual Recommended Angles for Overhead Fillet Welds 45˚ 15˚ 30˚ 17.7 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 ...
  • Page 46 BOC Smootharc TIG 200 ACDC 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 • a tighter weaving motion • complete slag removal before welding Lack of Fusion •...
  • Page 48 BOC is a trading name of BOC Limited, a subsidiary of Linde plc. © BOC Limited 2019. 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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