Linde BOC Smootharc Advance II MIG 250R Operating Manual
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Linde BOC Smootharc Advance II MIG 250R Operating Manual

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MIG 250R
Operating manual
Machine comes with side tray

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Summary of Contents for Linde BOC Smootharc Advance II MIG 250R

  • Page 1 MIG 250R Operating manual Machine comes with side tray...
  • Page 2 BOC Smootharc Advance II MIG 250R 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 the Smootharc ADVANCE machine.

  • Page 3: Table Of Contents

    BOC Smootharc Advance II MIG 250R Operating manual 1.0 Recommended Safety Guidelines and Precautions Health Hazard Information Personal Protection Contents. Electrical shock User Responsibility Switch on to electrical safety 2.0 Package Contents 3.0 Technical Specifications 4.0 Installation Installation for MIG/MAG process Installation for MMA process 5.0 Control panels...

  • Page 4: Recommended Safety Guidelines And Precautions

    BOC Smootharc Advance II MIG 250R 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 250R 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 BOC Smootharc Advance II MIG 250R 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 Advance II MIG 250R 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 Advance II MIG 250R 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 Advance II MIG 250R 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 Advance II MIG 250R Operating manual 2.0 Package Contents Package Contents Power source with input cable MIG Torch Binzel MB 24KD BOC Argon regulator Work return lead Wire feeder Interconnecting cable for wire feeder (10 m) Wire feed rollers Knurled 0.8-0.9/1.0-1.2...

  • Page 11: Technical Specifications

    BOC Smootharc Advance II MIG 250R Operating manual 3.0 Technical Specifications Specifications MIG/MAG Part No. ADVANCE II 250R-1 Input voltage Single phase 240 V ±15 % Frequency 50/60 Hz 46 A 44 A Maximum rated input current (I 1max Maximum effective supply current (I 27.2 A...

  • Page 12: Installation

    BOC Smootharc Advance II MIG 250R Operating manual 4.0 Installation Installation for MIG/MAG process Primary current rating IMPORTANT This machines has a maximum primary current input (I ) rating of 1max 46 amps. To obtain full rated output, they must be: This machine comes fitted with a 32A rated single phase plug connected to an approved plug and socket or for compliance to AS/NZ electrical regulations.

  • Page 13: Installation For Mma Process

    BOC Smootharc Advance II MIG 250R Operating manual Installation for MMA process 4.2 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 14: Control Panels

    BOC Smootharc Advance II MIG 250R Operating manual 5.0 Control panels Control panel of MIG 250R Control panel of wire feeder Voltage meter Wire inch button Power indicator light 2T/4T button Process selection switch Current meter/ Wire speed meter Wire speed...

  • Page 15: Inductance

    BOC Smootharc Advance II MIG 250R Operating manual 5.2 Inductance amount of inductance with spray-transfer will provide softer starts (the initial short-circuit) Inductance is defined as the rise in current temperature to above normal, 5.3 Synergic Control (One Knob Control) in any electrical circuit that results in the melting of the wire at some point.

  • Page 16: Operation Setup

    BOC Smootharc Advance II MIG 250R Operating manual 6.0 Operation Setup Front and back of wire feeder Front and back of power source 2T/4T switch Negative terminal Wire speed Process selection Thermal protection/fault indicator MIG torch euro connection Inductance adjustment...

  • Page 17: Troubleshooting And Fault Finding

    BOC Smootharc Advance II MIG 250R Operating manual 7.0 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 18: Replacement Parts

    BOC Smootharc Advance II MIG 250R Operating manual 8.0 Replacement Parts Suitability Description Part No. Torch Binzel MB EVO PRO 24 3m 012.0371.1 Wire Feed Rollers Self-Shielded Flux Cored Knurled 0.8–0.9 ADVANCEKNROL0809 Knurled 1.0–1.2 ADVANCEKNROL1012 Knurled 1.2–1.6 ADVANCEKNROL1216 Aluminium U Groove 0.8–0.9 ADVANCEUROL0809 U Groove 1.0–1.2...

  • Page 19: Periodic Maintenance

    BOC Smootharc Advance II MIG 250R Operating manual 9.0 Periodic Maintenance The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your MIG 250R welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables.

  • Page 20: Warranty Information

    BOC Smootharc Advance II MIG 250R Operating manual 10.0 Warranty Information 10.1 Terms of Warranty 10.3 Warranty Period The Smootharc ADVANCE II 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 21: Mig Process

    BOC Smootharc Advance II MIG 250R Operating manual 11.0 MIG Process Typical MIG set up Torch Torch trigger Shroud Gas diffuser Contact tip Welding wire Shielding Weld Droplets Weld pool 11.1 Introduction to Metal Inert Gas (MIG) Each gas or gas mixture has specific advantages and limitations. Other...
  • Page 22 BOC Smootharc Advance II MIG 250R 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 23: Introduction To Metal Cored Arc Welding (Mcaw)

    BOC Smootharc Advance II MIG 250R 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 11.3 Introduction to Metal Cored Although the efficiency differs by wire type and manufacturer it is typically between 75–85%.
  • Page 24 BOC Smootharc Advance II MIG 250R 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 25 BOC Smootharc Advance II MIG 250R Operating manual Schematic of Globular Transfer Schematic of Spray Transfer Gas shroud Shielding gas Wire Droplets Weld Splatter Large droplet Workpiece Workpiece of gravity. Carbon dioxide gas drops are dispersed haphazardly. With The current flows continuously because of the high voltage maintaining argon-based gases, the drops are not as large and are transferred in a long arc and short-circuiting cannot take place.

  • Page 26: Fundamentals Of Mig, Fcaw And Mcaw

    BOC Smootharc Advance II MIG 250R Operating manual Typical Metal Transfer Mode Cast and Helix Globular Spray Transfer Transfer Transfer Process Cast Metal Inert Gas ✓ ✕ ✓ Helix (MIG) Flux Cored ✓ ✓ ✓* (Gas Shielded) Cast – Diameter of the circle Flux Cored ✓...
  • Page 27 BOC Smootharc Advance II MIG 250R 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 28: Mma Process

    BOC Smootharc Advance II MIG 250R Operating manual 12.0 MMA Process Schematic of MMA process in operation 12.1 Process 12.2 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 29: Welding Technique

    BOC Smootharc Advance II MIG 250R Operating manual 12.3 Welding Technique BOC Smootharc 13 has provided in-built operating qualities which appeals to the beginner and experienced operator alike. Successful welding depends on the following factors: Electrodes and Typical Applications → selection of the correct electrode...
  • Page 30 BOC Smootharc Advance II MIG 250R 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 31: Types Of Joints

    BOC Smootharc Advance II MIG 250R 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 32 BOC Smootharc Advance II MIG 250R 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 33: Fillet Welds

    BOC Smootharc Advance II MIG 250R 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 34 BOC Smootharc Advance II MIG 250R 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 20–30° 20–30° 20–30° 20–30°...

  • Page 35: Typical Defects Due To Faulty Technique

    BOC Smootharc Advance II MIG 250R Operating manual Slag Inclusions Undercutting Lack of Fusion Correct selection of electrodes is important for vertical welding. → slag left on the previous weld pass → too large an electrode being used In overhead fillet welds, careful attention to technique is necessary to obtain a sound weld of good profile.
  • Page 36 BOC Smootharc Advance II MIG 250R Operating manual → using a travel speed slow enough so that the weld metal can completely fill all of the melted out areas of the base metal. Lack of Fusion Lack of fusion is when the weld metal is not fused to the base metal.

  • Page 37: General Welding Information

    BOC Smootharc Advance II MIG 250R Operating manual 13.0 General Welding Information 13.1 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...
  • Page 38 BOC Smootharc Advance II MIG 250R 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 39: Correct Application Techniques

    BOC Smootharc Advance II MIG 250R Operating manual 14.0 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 40 BOC Smootharc Advance II MIG 250R 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 41 BOC Smootharc Advance II MIG 250R Operating manual...
  • Page 42 BOC Smootharc Advance II MIG 250R Operating manual...
  • Page 44 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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