MIG 200C/275C/275R/350R Operating manual
BOC Smootharc Advance MIG 200C/275C/275R/350R 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 troublefree service.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Contents. 1.0 Recommended Safety Guidelines and Precautions 4 1.1 1.2 1.3 1.4 Health Hazard Information Personal Protection Electrical shock User Responsibility 5 5 6 6 2.0 MIG Operating Manual 7 2.1 Introduction to Metal Inert Gas (MIG) 2.2 Introduction to Flux Cored Arc Welding (FCAW) 2.3 Introduction to Metal Cored Arc Welding (MCAW) 2.4 Fundamentals of MIG, FCAW and MCAW 7 7 9 12 3.0 General Welding Information 14 3.
BOC Smootharc Advance MIG 200C/275C/275R/350R 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 Welding arc rays Some safety precautions BOC recommends are as follows: • Repair or replace defective cables immediately. Read instruction manual • Never watch the arc except through lenses of the correct shade.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 1.1 Health Hazard Information The actual process of MIG welding is one that can cause a variety of hazards. All appropriate safety equipment should be worn at all times, i.e. headwear, hand and body protection. Electrical equipment should be used in accordance with the manufacturer’s recommendations. Eyes The process produces ultra violet rays that can injure and cause permanent damage. Fumes can cause irritation.
1.3 BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Electrical shock • Never touch ‘live’ electrical parts 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.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 7 2.0 MIG Operating Manual Typical MIG set up Torch Torch trigger Shroud Gas diffuser Contact tip Welding wire Weld Shielding Droplets Weld pool 2.1 Introduction to Metal Inert Gas (MIG) MIG welding embraces a group of arc welding processes in which a continuous electrode (the wire) is fed by powered feed rolls (wire feeder) into the weld pool. An electric arc is created between the tip of the wire and the weld pool.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Extended self shielded flux cored wire nozzle Unlike MIG, which uses a solid consumable filler wire, the consumable used in FCAW is of tubular construction, an outer metal sheath being filled with fluxing agents plus metal powder. The flux fill is also used to provide alloying, arc stability, slag cover, de-oxidation, and, with some wires, gas shielding.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 9 Process Schematic Diagram for MIG / FCAW and MCAW Gas hose Continous wire Wire feed unit Power cable Torch conduit Gas cylinder Welding torch Arc Workpiece Power source Earth clamp Return cable efficiency varies differs by wire type and manufacturer it is typically between 75–85%.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Schematic of Dip Transfer 1 2 3 4 5 6 Short circuit Necking Arc re-ignition Arc established Arc gap shortens Short circuit 1 2 3 4 5 6 Time Current (A) Voltage (V) Short circuit cycle filled entirely with metal powder except for a small amount of nonmetallic compounds. These are added to provide some arc stability and de-oxidation. MCAW consumables always require an auxiliary gas shield in the same way that solid MIG wires do.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Schematic of Globular Transfer 11 Schematic of Spray Transfer Gas shroud Shielding gas Wire Droplets Large droplet Splatter Workpiece Globular Transfer Metal transfer is controlled by slow ejection resulting in large, irregularlyshaped ‘globs’ falling into the weld pool under the action of gravity. Carbon dioxide gas drops are dispersed haphazardly.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Typical Metal Transfer Mode Process Dip Transfer Cast and Helix Globular Transfer Spray Transfer Cast Metal Inert Gas (MIG) � � � Flux Cored (Gas Shielded) � � �* Flux Cored (Self Shielded) � � � Metal Cored � � � Helix Cast – Diameter of the circle Helix – Vertical height * Not True Spray 2.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 13 Selection of the Correct Power Source Power sources for MIG welding is selected on a number of different criteria, including: Selection of the Correct Shielding Gas The selection of the shielding gas has a direct influence on the appearance and quality of the weldbead. 1 Maximum output of the machine The thickness of the material to be welded will determine the type of shielding gas that has to be selected.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 3.0 General Welding Information 3.1 Recommended Welding Parameters Argoshield Light Indicative Welding Parameters Dip Transfer Material thickness (mm) 1–1.6 2 3 4 3 4 6 8–9 Welding position Horizontal / Vertical Horizontal / Vertical Horizontal / Vertical Horizontal / Vertical Horizontal Horizontal Horizontal Horizontal Wire diameter (mm) 0.8–0.9 0.8–0.9 0.8–0.9 0.9–1.0 0.8 0.9 1.0 1.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Argoshield Heavy Indicative Welding Parameters Dip Transfer Material thickness (mm) 10 12+ 10 12+ Welding position Horizontal/ Vertical Horizontal/ Vertical Horizontal Horizontal Wire diameter (mm) 1.2 1.2 1.2 1.2 Current (amps) 140–160 140–160 240–260 290–330 Voltage (volts) 17–18 17–18 27–29 28–31 Wire feed speed (m/min) 3.2–4.0 3.2–4.0 7.0–8.0 10.0–12.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 4.0 Correct Application Techniques Electrical stickout C S V A E Contact Tube Setback Standoff Distance Visible Stickout Arc length Electrical Stickout Gas Nozzle Contact Tube C Consumable S Electrode V E A Workpiece Correct Application Techniques Direction of welding. MIG welding with solid wires takes place normally with a push technique. The welding torch is tilted at an angle of 10° towards the direction of welding.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Electrical stickout Short Short Travel speed Normal Normal Long Long Torch position for fillet welds When welding fillet welds the torch should be positioned at an angle of 45° from the bottom plate with the wire pointing into the fillet corner. Welding is still performed in the push technique. Electrical stickout The electrical stickout is the distance between the end of the contact tip and the end of the wire.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 5.0 Package Contents Smootharc ADVANCE Range MIG 200C Power source with input cable and plug MIG Torch BOC Argon regulator Work return lead 1× gas hose 1× lifting lug MIG 275C MIG 275R MIG 350R � � � � Binzel MB Ergo 24KD Binzel MB Ergo 36KD Binzel MB Ergo 36KD Binzel ABIMIG 355 � � � � � � � � � � � � – – � � Wire feed rollers Knurled 0.8-0.9/1.0-1.2 0.8-0.9/1.0-1.2 0.8-0.9/1.0-1.2 0.8-0.9/1.0-1.2/1.2-1.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 6.0 Smootharc ADVANCE Installation Installation configuration of MIG 200C/275C 6.1 Compact Models Important Notice 275C and 275R 1 Connect the gas cylinder to the regulator. Select correct shielding gas for the application. Both the 275C & 275R come fitted with a 15A plug and lead. 2 Insert the earth return lead connection into the front panel.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Installation configuration of MIG 275R/350R Important Notice 275C and 275R Both the 275C & 275R come fitted with a 15A plug and lead. As stated on the label fitted to the lead, in order to obtain full rated output an electrician must fit the larger input cable supplied with the machine along with a 32 amp plug to an electrical circuit rated to at least 32 amps. 6.2 Remote Models 1 Connect the gas cylinder to the regulator.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 7.0 Smootharc ADVANCE Operation 7.1 Compact and Remote Models 1 Ensure the machine is correctly plugged into the main circuit.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 8.0 Control Panels Front Panel of MIG 200C/275C Power indicator led Voltage meter Current meter Gas purge button Wire inch button Current/Voltage/ Inductance button 2T/4T button Wire speed selection Parameters adjustment ON/OFF switch 8.1 Compact Models The easy-to-operate and understand machine front panel includes two LED displays for welding voltage and current/wire feed speed.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Front Panel of MIG 275R/350R 23 Front panel of wire feeder of MIG 275R/350R Power indicator led Voltage meter Wire inch button Current meter Gas purge button Voltage adjustment Inductance adjustment Wire speed adjustment 2T/4T button Wire speed selection ON/OFF switch 8.2 Remote models The easy-to-operate and understand machine front panel includes two LED displays for welding voltage and current/wire feed speed.
8.3 BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual Inductance Inductance is defined as the rise in current temperature to above normal, in any electrical circuit that results in the melting of the wire at some point. Consider dip transfer (short ¬circuiting arc) in action. Before the wire strikes the work-piece, there is no flow of current and the OCV has maximum value. When the wire strikes the work-piece it creates what is known as a “dead short”.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 25 9.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 10.0 Replacement Parts MIG 200C MIG 275C MIG 275R MIG 350R Suitability Description Part No. Torch � � � � Binzel MB Ergo 24KD Air Cooled 012.0104 Binzel MB Ergo 36KD Air Cooled 014.0144 Binzel ABIMIG 355 Air Cooled 014.H180 Wire Feed Rollers � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � Self-Shielded Flux Cored Aluminium Steel, Stainless Steel Knurled 0.8-0.9 ADVANCE KN ROL 0809 Knurled 1.0-1.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 11.0 Periodic Maintenance The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your Smootharc ADVANCE welder. Preventative maintenance will ensure trouble-free welding and increase the life of the machine and its consumables. 11.1 Power Source • Check electrical connections of unit at least twice a year. • Clean oxidised connections and tighten.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 12.0 Technical Specifications Specifications Part No. Power Vol Frequency Output current Output Voltage Duty cycle 35 % 60 % Power factor Efficiency Wire machine Wire speed Wire spool diameter Wire diameter Housing shielding grade Insulation grade Suitable thickness Dimensions L x W x H Weight approx. Power source Wire feeder Standards MIG 200C MIG 275C MIG 275R MIG 350R ADVANCE 200C Single phase 240 V ±15 % 50/60 Hz 50 to 200 A 16.
BOC Smootharc Advance MIG 200C/275C/275R/350R Operating manual 29 13.0 Warranty Information 13.1 Terms of Warranty 13.3 Warranty Period The Smootharc ADVANCE machine has a limited warranty that covers manufacturing and material defects only. The warranty is affected on the day of purchase and does not cover any freight, packaging and insurance costs. Verbal promises that do not comply with terms of warranty are not binding on warrantor.
For more information contact the BOC Customer Service Centre. BOC Australia 131 262 contact@boc.com BOC Limited 10 Julius Avenue, North Ryde NSW 2113, Australia www.boc.com.au 970–988 Great South Road, Penrose, Auckland, New Zealand www.boc.co.nz © BOC Limited 2010. BOC is a trading name of BOC Limited, a Member of The Linde Group. Reproduction without permission is strictly prohibited.Details given in this document are believed to be correct at the time of printing.
