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Summary of Contents for BOC Smootharc Advance II
- Page 1 MIG 200C & 250C Operating manual Machines come with side tray...
- Page 2 This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’), as general information and does not contain and is not to be taken as containing any specific recommendation. The document has been prepared in good faith...
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Page 3: Table Of Contents
BOC Smootharc Advance II MIG 200C & 250C Operating manual Recommended Safety Guidelines and Precautions Health Hazard Information Contents. 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 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 → 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: 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 7: Mig Process
BOC Smootharc Advance II MIG 200C & 250C 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 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.
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Page 9: 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 2.3 Introduction to Metal Cored... - Page 10 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...
- Page 11 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 Globular Transfer welding. The main exception is aluminium and its alloys where, primarily...
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Page 12: 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 13 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.
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Page 14: Mma Process
BOC Smootharc Advance II MIG 200C & 250C 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 S 309L E309L Rutile basic coated low carbon electrode mild steel and for this material has a choice of various standard BOC for welding mild steel to stainless steel and difficult to weld material electrodes, each of which will have qualities suited to particular tasks. - Page 16 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.
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Page 17: 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... - Page 18 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.
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Page 19: 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... - Page 20 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˚...
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Page 21: 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. → slag left on the previous weld pass In overhead fillet welds, careful attention to technique is necessary to →... - Page 22 BOC Smootharc Advance II MIG 200C & 250C Operating manual → holding the arc as short as possible → pausing at each side of the weld bead when a weaving technique is used → using a travel speed slow enough so that the weld metal can completely fill all of the melted out areas of the base metal.
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Page 23: General Welding Information
BOC Smootharc Advance II MIG 200C & 250C Operating manual 4.0 General Welding Information 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... - Page 24 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...
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Page 25: Correct Application Techniques
BOC Smootharc Advance II MIG 200C & 250C 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 Flux cored welding with cored wires takes place normally with the drag technique. - Page 26 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.
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Page 27: Package Contents
BOC Smootharc Advance II MIG 200C & 250C Operating manual 6.0 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 36KD ✓... -
Page 28: Installation
BOC Smootharc Advance II MIG 200C & 250C Operating manual 7.0 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) -
Page 29: Operation Set-Up
BOC Smootharc Advance II MIG 200C & 250C Operating manual 8.0 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... -
Page 30: Control Panel
BOC Smootharc Advance II MIG 200C & 250C Operating manual 9.0 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... -
Page 31: Inductance
BOC Smootharc Advance II MIG 200C & 250C Operating manual 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 32: Troubleshooting And Fault Finding
BOC Smootharc Advance II MIG 200C & 250C 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 33: Replacement Parts
BOC Smootharc Advance II MIG 200C & 250C Operating manual 11.0 Replacement Parts MIG 200C MIG 250C Suitability Description Part No. Torch ✓ Binzel MB EVO PRO 24 3m 012.0371.1 ✓ Binzel MB36KD Air Cooled 3m 014.0234 Wire Feed Rollers ✓... -
Page 34: Periodic Maintenance
BOC Smootharc Advance II MIG 200C & 250C 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 MIG 200C or 250C welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables. -
Page 35: Technical Specifications
BOC Smootharc Advance II MIG 200C & 250C Operating manual 13.0 Technical Specifications 200C Specifications MIG/MAG 250C Specifications MIG/MAG Part No. ADVANCE II 200C Part No. ADVANCE II 250C Power voltage Single phase 240 V ±15 % Power voltage Single phase 240 V ±15 %... -
Page 36: Warranty Information
Warranty repairs may only be carried out by approved BOC service damage due to or resulting from natural wear and tear, non-compliance providers. Please contact your local BOC Gas & Gear for a directory of BOC with operating and maintenance instructions, connection to incorrect approved service providers in your area. - Page 37 BOC Smootharc Advance II MIG 200C & 250C Operating manual...
- Page 38 BOC Smootharc Advance II MIG 200C & 250C Operating manual...
- 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.
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