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Summary of Contents for BOC Smootharc Multi 180
- Page 1 Multi 180/200 Operating manual This machine is to be used only by appropriately trained operators in industrial applications. This product is an arc welding machine designed for INDUSTRIAL AND PROFESSIONAL USE.
- 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 and is professional opinion only. Information in this document has been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOC makes no representation or warranty as to the accuracy, reliability or completeness of information in this document and does not assume any responsibility for updating any information or correcting any error or omission which may become apparent after the document has been issued.
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Page 3: Table Of Contents
BOC Smootharc Multi 180/200 Operating manual Contents Safety guidelines and precautions Metal Inert Gas (MIG) and Metal Active Gas (MAG) welding Health hazard information Introduction Personal protection Flux Cored Arc Welding (FCAW) Cylinder safety Metal Cored Arc Welding (MCAW) Cylinder valve safety Metal transfer modes Electrical shock... -
Page 4: Safety Guidelines And Precautions
BOC Smootharc Multi 180/200 Operating manual Safety guidelines and precautions → Repair or replace defective cables immediately. → Never watch the arc except through lenses of the correct shade. → In confined spaces, adequate ventilation and constant observation are essential. →... -
Page 5: Health Hazard Information
BOC Smootharc Multi 180/200 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 such as stainless steel, nickel, nickel alloys or galvanised steel, The actual process of welding is one that can cause a variety of hazards. -
Page 6: Cylinder Safety
DO NOT use ammonia- based leak detection fluid as this can damage the valve. Approved leak detection fluid, can be obtained from a BOC Gas & Gear centre. When finished with the cylinder, close the cylinder valve by hand by turning the valve hand-wheel in a clockwise direction. -
Page 7: Electrical Shock
BOC Smootharc Multi 180/200 Operating manual Electrical shock BOC stock a huge range of personal protective equipment. This combined with BOC’s extensive retail 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
Before operating your welding machine, follow the instructions in the operating manual provided. For more information refer to WTIA TN 22 – Welding Electrical Safety (Revised 2003) and WTIA TN 07 Health & Safety in Welding. If you have any queries please contact BOC 131 262 (AU), 1800 111 333 (NZ). - Page 9 Australian and New Zealand regulations check for this symbol before buying any welding regarding electrical safety. The triangle-circle- machine in Australia and New Zealand. tick (RCM) symbol signifies that BOC has taken Don‘t Check the rating plate on your machine ✖...
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Page 10: Package Contents
BOC Smootharc Multi 180/200 Operating manual Package contents Spool gun Smootharc 180 Multiprocess Smootharc 200 Multiprocess Power source with input cable and plug Binzel MB15KD 3 m MIG torch Binzel MB24KD 3 m MIG torch BOC Argon regulator 3 m work return lead... -
Page 11: Technical Specifications
BOC Smootharc Multi 180/200 Operating manual Technical specifications Specifications 180 Multiprocess 200 Multiprocess Part No. BOC180MULTILCD BOC200MULTILCD Input voltage Single phase 240 V ±15 % Single phase 240 V ±15 % Frequency 50/60 Hz 50/60 Hz Maximum rated input current (I... -
Page 12: Installation
BOC Smootharc Multi 180/200 Operating manual Installation Installation for MIG/MAG process Wire feed installation Wire inch button Wire spool holder Wire feed unit MIG/MAG 7. Fit and tighten the [A] torch on the [10] output connection. Ensure correct torch liner and contact tip are selected. -
Page 13: Mig With Spool Gun
MIG with spool gun (Aluminium only) Spool compatibility The BOC Smootharc 180 & 200 models take both D200 and D100 size spools in the internal wire feeder and D100 in the spool gun for 1. Select correct shielding gas for the application. Connect the gas aluminium wire only. -
Page 14: Mma
DCEN. work piece. Setup using optional foot control Part No BOC/FC/LCD The optional foot pedal switch [H], sold separately, can be used for arc start control and welding current regulation. Welding current will switch automatically to foot pedal control after the control plug is connected to welder’s control cable socket. -
Page 15: Control Panel
BOC Smootharc Multi 180/200 Operating manual Control panel Front panel of Multi 180/200 machines Multifunctional data display Main menu Previous window Data adjusting knob (left) Menu selection and adjustment knob (centre) Data adjusting knob (right) Description Function Multifunctional data display. -
Page 16: Operation
BOC Smootharc Multi 180/200 Operating manual Operation Starting up Main menu options 1. Ensure the machine is correctly plugged into the main circuit. 2. Proper PPE must be worn. 3. Ensure workplace safety, such as fume extraction and welding curtains are in place. - Page 17 BOC Smootharc Multi 180/200 Operating manual...
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Page 18: Mig/Mag Modes
BOC Smootharc Multi 180/200 Operating manual MIG/MAG modes MIG/MAG Steel Mix, MAG Steel CO₂, Flux Cored, MIG/MAG Stainless Steel, MIG/MAG Manual. Press main Turn centre Press centre menu button. selection knob and knob to confirm. select MIG/MAG function. Screen showing Press centre gas will appear. - Page 19 BOC Smootharc Multi 180/200 Operating manual Turn and press centre knob to select Run-In WFS. Adjust % figure by Press centre turning centre knob. knob to confirm. Turn and press centre knob to select Inductance. Adjust figure by Press centre turning centre knob. knob to confirm.
- Page 20 BOC Smootharc Multi 180/200 Operating manual Turn and press centre knob Press centre to select Spot Timer. knob to confirm. Using centre knob set Press centre Spot Timer at: knob to confirm. 0 sec for 2T function 0.1 sec for 4T function >0.1 sec for spot welding.
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Page 21: Mig Mode For Aluminium Wire (Spool Gun)
BOC Smootharc Multi 180/200 Operating manual MIG mode for aluminium wire (spool gun) This machine uses aluminium wire through a spool gun. Please ensure to installation section of this manual. To operate, please follow same you have installed the spool gun before welding with aluminium. Refer steps as 6.2 MIG Mode and select spool gun options. - Page 22 BOC Smootharc Multi 180/200 Operating manual Select your electrode Press centre type centre knob. knob to confirm. Select your Select plate Press centre electrode diameter thickness using knob to confirm. using left knob. right knob. Window shows “Output is off”.
- Page 23 BOC Smootharc Multi 180/200 Operating manual To switch output to “On” press centre knob. Window will appear. Turn right knob anti- Press centre knob clockwise to switch to “On”. to confirm. Press and turn centre knob to select Hot Start. Press centre...
- Page 24 BOC Smootharc Multi 180/200 Operating manual Press and turn centre knob to select ARC Force. Press centre Turn to adjust Press again ARC Force. knob to confirm. to confirm. Press and turn centre knob to select Recall Setting. Press and turn centre knob to select Save Setting.
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Page 25: Tig Mode
BOC Smootharc Multi 180/200 Operating manual TIG mode Press main Turn centre Press centre menu button. selection knob and knob to confirm. select TIG function. Screen will show Press centre “100% Argon”. knob to confirm. Select your electrode diameter using left knob. Select plate thickness Press centre knob ... - Page 26 BOC Smootharc Multi 180/200 Operating manual Window shows “Output is off”. To switch output to “On” press centre knob. Window will appear. Turn right knob anti- Press centre knob clockwise to switch to “On”. to confirm.
- Page 27 BOC Smootharc Multi 180/200 Operating manual Press and turn centre knob to select Recall Setting. Press and turn centre knob to select Save Setting. Optional foot control If using optional foot control please ensure this is installed before welding. Refer to installation section.
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Page 28: Settings
BOC Smootharc Multi 180/200 Operating manual Settings Use this option for adjusting Units, Brightness, view software version, and Factory Reset. Error codes If you exceed the machine’s duty cycle it will stop operating. Allow the machine to cool before resuming welding. -
Page 29: Inductance
BOC Smootharc Multi 180/200 Operating manual Inductance 4T/2T trigger latch selection Inductance in welding is the control of current surges during short On all MIG machines there is no current or wire feed until the trigger on circuits. Consider dip transfer (short-circuiting arc) in action. The wire the torch is depressed. -
Page 30: Troubleshooting And Fault Finding
BOC Smootharc Multi 180/200 Operating manual Troubleshooting and fault finding Failure Analysis Troubleshooting No wire when torch No power. Investigate reasons for no power. trigger is pressed. Torch trigger is broken. Change the torch. Arc is unstable, and Welding parameters are incorrect. Current and Adjust welding parameters. -
Page 31: Periodic Maintenance
BOC Smootharc Multi 180/200 Operating manual Periodic maintenance The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of this machine. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables. -
Page 32: Warranty Information
The following conditions are not covered under terms of warranty: loss or claim. Warranty repairs may only be carried out by approved BOC service damage due to or resulting from natural wear and tear, non-compliance providers. -
Page 33: Metal Inert Gas (Mig) And Metal Active Gas (Mag) Welding
BOC Smootharc Multi 180/200 Operating manual Metal Inert Gas (MIG) and Metal Active Gas (MAG) welding Typical MIG/MAG set up Torch Torch trigger Shroud Gas diffuser Contact tip Welding wire Shielding Weld Droplets Weld pool Introduction Successful welding depends the correct selection of consumables, power... - Page 34 BOC Smootharc Multi 180/200 Operating manual Extended self shielded flux cored wire nozzle In terms of gas shielding, there are two different ways in which this may To bring the welding current back to 250 amps it is necessary to be achieved with the FCAW process.
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Page 35: Metal Cored Arc Welding (Mcaw)
BOC Smootharc Multi 180/200 Operating manual Process schematic diagram for MIG/MAG, FCAW and MCAW Gas hose Continuous wire Wire feed unit Power cable Torch conduit Gas cylinder Welding torch Workpiece Earth clamp Power source Return cable If no external gas shield is required, then the flux fill must provide... -
Page 36: Metal Transfer Modes
BOC Smootharc Multi 180/200 Operating manual Typical metal transfer mode Schematic of dip transfer Globular Spray Short circuit Transfer Transfer Transfer Process Necking Arc re-ignition Metal Inert Gas (MIG) ✓ ✘ ✓ Arc established Metal Active Gas (MAG) Arc gap shortens Short circuit ✓... - Page 37 BOC Smootharc Multi 180/200 Operating manual Schematic of globular transfer Schematic of spray transfer Gas shroud Shielding gas Wire Droplets Weld Splatter Large droplet Workpiece Workpiece Spray transfer Rutile flux-cored wires will operate in this almost-spray transfer mode, at all practicable current levels. They are also able to operate in this mode In spray transfer, metal is projected by an electromagnetic force from for positional welding too.
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Page 38: Consumables
Power sources The following table gives a general overview of the selection of some of the BOC range of MIG/MAG wires for the most common materials. Power sources for MIG/MAG welding is selected on a number of different criteria, including: Common materials welded with BOC MIG wire →... -
Page 39: Polarity
BOC Smootharc Multi 180/200 Operating manual Polarity 4T/2T trigger latch selection Many power sources are fitted with an optional reverse polarity On all MIG machines there is no current or wire feed until the trigger dinse connector. To achieve the optimum welding it is important on the torch is depressed. -
Page 40: Correct Application Techniques
BOC Smootharc Multi 180/200 Operating manual Electrical stickout Travel speed Contact Tube Setback Slow Normal Fast Standoff Distance Visible Stickout Arc length Electrical Stickout Gas Nozzle Contact Tube Slow Normal Fast Consumable Electrode Workpiece Short Normal Long Short Normal Long... -
Page 41: Recommended Mig/Mag Welding Parameters
BOC Smootharc Multi 180/200 Operating manual Recommended MIG/MAG welding parameters Argoshield Light Indicative Spray welding parameters Dip transfer transfer Material thickness (mm) 1–1.6 Welding position Horizontal / Horizontal / Horizontal / Horizontal / Horizontal Vertical Vertical Vertical Vertical Wire diameter (mm) 0.8–0.9... -
Page 42: Gas Tungsten Arc Welding (Gtaw/Tig)
BOC Smootharc Multi 180/200 Operating manual Gas Tungsten Arc Welding (GTAW/TIG) Schematic of the TIG welding process Collet Shielding gas Tungsten electrode TIG filler rod Weld pool Workpiece Introduction The Tungsten Inert Gas, or TIG process, uses the heat generated by an... - Page 43 BOC Smootharc Multi 180/200 Operating manual Process variable Explanation Usage DCEN When direct-current electrode-negative (straight polarity) For a given diameter of tungsten electrode, higher is used: amperage can be used with straight polarity. Straight Narrow bead, polarity is used mainly for welding: deep penetration...
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Page 44: Shielding Gases
BOC Smootharc Multi 180/200 Operating manual Shielding gases Welding wire The following table includes the recommended welding consumable for Material Shielding gas Benefits the most commonly welded materials. Brass Argon Stable arc Base material BOC consumable Low fume Cobalt-based alloys Argon... -
Page 45: Tungsten Electrodes
BOC Smootharc Multi 180/200 Operating manual Tungsten electrodes Thickness Welding Base metal type range Desired results current Electrode type Shielding gas Tungsten performance characteristics Copper alloys, General purpose DCSP 2% Thoriated 75% Argon/ Best stability at medium currents. Good arc... - Page 46 BOC Smootharc Multi 180/200 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.
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Page 47: Techniques For Successful Tig Welding
BOC Smootharc Multi 180/200 Operating manual Techniques for successful TIG welding Torch movement during welding TIG welding techniques Tungsten without filler rod Tungsten with filler rod Welding direction Welding Vertical 75° direction Welding Rod 60–75° 75° Form pool Form pool... -
Page 48: Positioning Torch Tungsten For Various Weld Joints
90° BOC Smootharc Multi 180/200 Operating manual 90° 70° 90° 90° 20° 70° 90° 20° 20° 20° 20° 20° 20° 75° 75° 20° 75° 15° 75° 15° 10° 15° 10° 15° 10° 70° 90° 10° 70° Positioning torch tungsten for various weld joints 90°... -
Page 49: Joint Preparation
BOC Smootharc Multi 180/200 Operating manual 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... - Page 50 BOC Smootharc Multi 180/200 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...
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Page 51: Manual Metal Arc Welding (Mmaw)
(the electrode). The heat of the arc melts the BOC offers a popular range of arc welding machines ranging from small parent metal and the electrode which mix together to form, on cooling, 240V portable welders to heavy-duty welders used by the largest a continuous solid mass. -
Page 52: Electrode Type And Size
BOC Smootharc 24 E7024 in low carbon steels mild steel and for this material has a choice of various standard BOC A premium quality all positional hydrogen electrodes, each of which will have qualities suited to particular tasks. controlled electrode for carbon steels in... -
Page 53: Welding Current
Certain BOC electrodes have been specially designed for ‘touch’ current in the middle of the range specified on the electrode package is welding. -
Page 54: Travel Speed
Various types of butt welds are in common use and their suitability for inclusions and poor mechanical properties. different thickness of steel are described as follows: Run length per electrode – BOC Smootharc 13 Square Butt Weld Run Length (mm) - Page 55 BOC Smootharc Multi 180/200 Operating manual Welding progression angle Electrode 70–85˚ Weld Metal Slag Weld Pool Workpiece Direction of Welding Butt welds should be overfilled to a certain extent by building up Used on thick plates an alternative to a single ‘V’ preparation.
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Page 56: Fillet Weld Types
BOC Smootharc Multi 180/200 Operating manual Convex fillet weld Concave fillet weld CONVEXITY ACTUAL THROAT SIZE CONVEXITY ACTUAL THROAT CONCAVITY SIZE LENGH ACTUAL THROAT CONCAVITY AND EFFECTIVE LENGH SIZE LEG ACTUAL THROAT THROAT EFFECTIVE THROAT AND EFFECTIVE SIZE LEG THROAT... - Page 57 BOC Smootharc Multi 180/200 Operating manual Convex Fillet Weld Fillet Weld Data A fillet weld in which the contour of the weld metal lies outside a straight line joining the toes of the weld. A convex fillet weld of Nominal...
- Page 58 Multi-run Fillet current used is medium, penetration is poor, each run is small, concave and smooth (only BOC Smootharc 13 is suitable for this position). The downwards method should be used for making welds on thin material only. Electrodes larger than 4.0 mm are not recommended for vertical down welding. All strength joints in vertical plates 10.0...
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Page 59: Typical Defects Due To Faulty Technique
BOC Smootharc Multi 180/200 Operating manual Typical defects due to faulty technique Undercutting Manual metal arc welding, like other welding processes, has welding procedure problems that may develop which can cause defects in the weld. Some defects are caused by problems with the materials. Other welding problems may not be foreseeable and may require immediate corrective action. - Page 60 © BOC Limited 2023. BOC is a trading name of BOC Limited, a Linde company. 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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