Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Linde BOC Smootharc Advance MIG 200C
Summary of Contents for Linde BOC Smootharc Advance MIG 200C
- Page 1 MIG 200C & 250C Operating manual Machines come with side tray...
- Page 2 BOC Smootharc Advance II MIG 200C & 250C 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 machines. With normal use and by following these recommended steps, your Smootharc ADVANCE machine can provide you with years of trouble- free service.
-
Page 3: Table Of Contents
BOC Smootharc Advance II MIG 200C & 250C Operating manual 1.0 Recommended Safety Guidelines and Precautions Health Hazard Information Contents. Personal Protection 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 Panel Controls... -
Page 4: Recommended Safety Guidelines And Precautions
BOC Smootharc Advance II MIG 200C & 250C 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 200C & 250C Operating manual Health Hazard Information such as stainless steel, nickel, nickel alloys or galvanised steel, further precautions are necessary. The actual process of MIG welding is one that can cause a variety of →... - Page 6 BOC Smootharc Advance II MIG 200C & 250C 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...
-
Page 7: Electrical Shock
BOC Smootharc Advance II MIG 200C & 250C 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 200C & 250C 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 200C & 250C 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 200C & 250C Operating manual 2.0 Package Contents MIG 200C Package Contents MIG 250C Package Contents ✓ ✓ Power source with input cable Power source with input cable MIG Torch Binzel MB 24KD MIG Torch Binzel MB 24KD ✓... -
Page 11: Technical Specifications
BOC Smootharc Advance II MIG 200C & 250C Operating manual 3.0 Technical Specifications 200C Specifications MIG/MAG 250C Specifications MIG/MAG Part No. ADVANCE II 200C Part No. ADVANCE II 250C-1 Power voltage Single phase 240 V ±15 % Power voltage Single phase 240 V ±15 % Frequency 50/60 Hz Frequency... -
Page 12: Installation
BOC Smootharc Advance II MIG 200C & 250C Operating manual 4.0 Installation Installation for MIG/MAG process Installation for MMA process 200C Smootharc Smootharc Advance Advance Advance Advance m/min CURRENT INDUCTANCE INDUCTANCE WIRE SPEED VOLTAGE 8 For torch positive, plug the short mechanical connector (link plug) IMPORTANT on the front panel into the positive (+) terminal and the work return lead... -
Page 13: Control Panel
BOC Smootharc Advance II MIG 200C & 250C Operating manual 5.0 Control Panel Control Panel of MIG 200C & 250C Voltage meter 200C Smootharc Advance Advance Power indicator light 2T/4T button Process selection switch m/min Current meter/ Wire speed meter Inductance Knob CURRENT INDUCTANCE... -
Page 14: Inductance
BOC Smootharc Advance II MIG 200C & 250C Operating manual 5.2 Inductance Inductance is defined as the rise in current to above normal, in any Summarising, inductance has the following effects: electrical circuit that results in the melting of the wire at some point. →... -
Page 15: Operation Set-Up
BOC Smootharc Advance II MIG 200C & 250C Operating manual 6.0 Operation Set-up Front of MIG 200C & 250C Inside of MIG 200C & 250C Wir e Inch Process selection switch (MMA, MIG) Voltage Current and Wire feed speed Inductance Positive dinse connector Negative dinse connector Pigtail... -
Page 16: Troubleshooting And Fault Finding
BOC Smootharc Advance II MIG 200C & 250C 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 Damaged, loose or undersized cables and clamps Connectors and lugs Overheating of connectors and lugs... -
Page 17: Replacement Parts
BOC Smootharc Advance II MIG 200C & 250C Operating manual 8.0 Replacement Parts MIG 200C MIG 250C 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 ✓... -
Page 18: Periodic Maintenance
BOC Smootharc Advance II MIG 200C & 250C 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 200C or 250C welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables. -
Page 19: Warranty Information
BOC Smootharc Advance II MIG 200C & 250C 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 20: Mig Process
BOC Smootharc Advance II MIG 200C & 250C 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 forms of MIG welding include using a flux-cored continuous electrode MIG welding embraces a group of arc welding processes in which a and carbon dioxide shielding gas, or using self-shielding flux-cored wire,... - Page 21 BOC Smootharc Advance II MIG 200C & 250C 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 22: Introduction To Metal Cored Arc Welding (Mcaw)
BOC Smootharc Advance II MIG 200C & 250C 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 23 BOC Smootharc Advance II MIG 200C & 250C 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, which uses a solid consumable filler wire, the consumable The most common modes of transfer in FCAW are: used in MCAW is of tubular construction, an outer metal sheath being →...
- Page 24 BOC Smootharc Advance II MIG 200C & 250C 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 25: Fundamentals Of Mig, Fcaw And Mcaw
BOC Smootharc Advance II MIG 200C & 250C 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 26 BOC Smootharc Advance II MIG 200C & 250C 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 27: Mma Process
BOC Smootharc Advance II MIG 200C & 250C 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 28: Welding Technique
BOC Smootharc Advance II MIG 200C & 250C Operating manual 12.3 Welding Technique 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 Name Application... - Page 29 BOC Smootharc Advance II MIG 200C & 250C 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 30: Types Of Joints
BOC Smootharc Advance II MIG 200C & 250C 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 Weld Pool Slag... - Page 31 BOC Smootharc Advance II MIG 200C & 250C 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 32: Fillet Welds
BOC Smootharc Advance II MIG 200C & 250C 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 Size... - Page 33 BOC Smootharc Advance II MIG 200C & 250C 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˚...
-
Page 34: Typical Defects Due To Faulty Technique
BOC Smootharc Advance II MIG 200C & 250C 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 obtain a sound weld of good profile. - Page 35 BOC Smootharc Advance II MIG 200C & 250C 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.
-
Page 36: General Welding Information
BOC Smootharc Advance II MIG 200C & 250C 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 16–18... - Page 37 BOC Smootharc Advance II MIG 200C & 250C 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 10.0–10.6 10.2–10.8...
-
Page 38: Correct Application Techniques
BOC Smootharc Advance II MIG 200C & 250C 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 39 BOC Smootharc Advance II MIG 200C & 250C 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.
- Page 40 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.