Linde BOC Smootharc TIG 200 ACDC, Operating Manual

Page 1: ...Smootharc TIG200 ACDC Operating manual 6PRRWKDUF GY GY ...

Page 2: ...ty for updating any information or correcting any error or omission which may become apparent after the document has been issued Neither BOC nor any of its agents has independently verified the accuracy of the information contained in this document The information in this document is commercial in confidence and is not to be reproduced The recipient acknowledges and agrees that it must make its ow...

Page 3: ...0 2 4T operation mode 20 11 0 Installation Operation for MMA use 21 11 1 Installation and Operation for MMA welding 21 12 0 Troubleshooting and fault finding 22 13 0 Periodic maintenance 23 13 1 Power source 23 14 0 Warranty information 24 14 1 Terms of warranty 24 14 2 Limitations on warranty 24 14 3 Warranty period 24 14 4 Warranty repairs 24 15 0 Gas tungsten arc welding GTAW TIG 25 15 1 Introd...

Page 4: ...uipment at a handy location in the workshop Keep primary terminals and live parts effectively covered Never strike an arc on any gas cylinder Never use oxygen for venting containers Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming from welding process Welding arc rays Read instruction manual Become trained Wear dry insulated glo...

Page 5: ...ave enough ventilation in confined spaces Be alert to this at all times Keep your head out of the fumes rising from the arc 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 further precautions are necessary Wear a respirator when natural or forced v...

Page 6: ...ransit Before operating a cylinder valve Ensure that the system you are connecting the cylinder into is suitable for the gas and pressure involved Ensure that any accessories such as hoses attached to the cylinder valve or the system being connected to are securely connected A hose for example can potentially flail around dangerously if it is accidentally pressurised when not restrained at both en...

Page 7: ... may endanger the technician and operator and will void your warranty Only qualified personnel approved by BOC should perform repairs Always disconnect mains power before investigating equipment malfunctions Parts that are broken damaged missing or worn should be replaced immediately Equipment should be cleaned periodically BOC stock a huge range of personal protective equipment This combined with...

Page 8: ...ated supply current AS60974 1 Formula in clause 3 33 Maximum effective supply current I1eff I1 2 X I0 2 1 X The I1eff determines the correct plug input cable and input current required for each machine 10A I1eff I1eff I1eff I1eff 1 5 2 5mm2 min max cable size size must be indicated on the cable 15A 1 5 4mm2 25A 2 5 6mm2 32A 4 10mm2 Before operating your welding machine follow the instructions in t...

Page 9: ...hat comply with IEC60974 or AS60974 must have a rating plate similar to the one shown Welding machines draw some current when idle not welding and a higher current when welding Effective rated primary current I1eff combines the conductor heating due to these two levels of current I1eff is the maximum rated effective supply current that determines the minimum plug and input cable rating as well as ...

Page 10: ...Smootharc TIG 200 ACDC Operating Manual 2 0 Package contents Package Contents Power source Work return lead TIG torch Regulator Gas hose Operator s manual Optional Accessories Part No Foot control 340050 00018 ...

Page 11: ...70A Welding current range 3 210 A 10 170 A MMA ARC force current 0 100 A MMA hot start current 0 100 A Pre gas time 0 01 9 99 s Up slope time 0 10 s Down slope time 0 15 s Post gas time 0 1 60 s TIG mode ARC starting type HF LIFT Arc strike current 40 100 A Arc starting current 3 210 A Base current 3 210 A Crater filling current 10 210 A AC frequency 10 250 Hz Pulse frequency 0 2 500 Hz Clean rati...

Page 12: ...th work piece 3 Gas outlet Connect with TIG torch gas connector 4 Control socket Connect with TIG torch foot pedal or control cable of automation system 5 Power switch Use this switch to supply single phase 230V AC power for welding machine When switch is ON control panel will light up and the fan begins to run 6 Power supply cable Comes with a 15A plug 7 Gas inlet Connect gas regulator via gas ho...

Page 13: ...ol 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 When the pedal is used the welder begins to work at the welding current in accordance with pressure on the pedal The maximum current value is preset by the potentiometer on the foot pedal PLEASE NOTE The foot control pedal is sold se...

Page 14: ...between constant current and pulse When the indicator light is ON it s in pulse mode When the indicator light is OFF it s in constant current mode 5 Operating mode selection button on TIG mode select between 2T 4T 6 Parameter selection knob rotate clockwise to select from left to right anti clockwise to select from right to left 7 Parameter adjustment knob adjust selected parameter Rotate clockwis...

Page 15: ...rameter value 7 Open gas valve of gas regulator 8 Press parameter selection knob and pulse selection button at the same time for 3 second to enter into gas test mode Adjust flow meter knob of gas regulator to suitable value 9 Press torch switch and start welding 7 0 Operation for TIG welding Control panel TIG welding parameters Gas Regulator 6 95 7 6HOHFWLRQ GMXVWPHQW UF RUFH HOGLQJ PRGH XQFWLRQ 3...

Page 16: ...G 200 ACDC Selection Adjustment Arc Force F Welding mode A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F Torch operation mode A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A 1 Press the bottom left button to select function HF TIG Lift TIG 3 Press the bottom right button to select torch operation mode 2T 4T 5 Rotate the...

Page 17: ...n Adjustment Arc Force F A A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F Hz 8 Rotate the left knob to select Current 9 Rotate the right knob to adjust welding current according to work piece thickness 10 Rotate the left knob to select Clean Ratio 11 Rotate the right knob to adjust clean ratio The higher the ratio is the better the...

Page 18: ...election Adjustment Arc Force F Pulse A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F Torch operation mode A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A 9 0 Operation for DC Pulse TIG welding A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A 1 Press the bottom left button to select function HF TIG Lift TIG 2 Press the top left button to select welding mode DC 4 Press...

Page 19: ...Arc Force F Hz 11 Select Base Current 12 Adjust Base Current A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A A S Hz VRD TIG 200 ACDC Selection Adjustment Arc Force F A 9 Rotate the left knob to select Current peak current 10 Rotate the right knob to adjust welding current peak current 11 Rotate the left knob to select Base Current 12 Rotate the right knob to adjust base current 13 Rotat...

Page 20: ... and arc starts Output current starts at initial current and time of initial current Output depends on the time that torch trigger is pressed and held 2 Release torch trigger Output current increases from initial current to welding current This time is called up slope time If the initial current is not required the torch trigger does not need to be held Quickly press torch trigger to start arc the...

Page 21: ...are adjustable Rotate parameter selection knob to choose these parameters Rotate parameter adjustment knob to adjust these parameters 7 Rotate parameter adjustment knob to adjust welding current value in MMA mode 8 Start welding Electrode holder not included in this package 3 2 4 1 A S Hz VRD TIG 200 ACDC Selec tio Adju stme Arc Force F 11 0 Installation Operation for MMA use Control panel use in ...

Page 22: ... not adjustable 1 Display board is damaged 2 Main control board is damaged 3 Foot pedal is damaged Check and replace 6 Display E04 overheat protection 1 Welding current is too high 2 Environmental temperature is too high 1 Change on open load mode and cool down 2 Change on open load mode and cool down 3 Temperature relay is damaged 3 Replace 7 Display E02 Switch is abnormal 1 Torch trigger or foot...

Page 23: ... taken into consideration when planning maintenance frequency of your Smootharc welder Preventative maintenance will ensure trouble free welding and increase the life of the machine and its consumables 13 1 Power source Check electrical connections of unit at least twice a year Repair or replace broken damaged cables Clean oxidised connections and tighten Inner parts of machine should be cleaned w...

Page 24: ... daily allowances or accommodation and travelling costs Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void NOTE Under the terms of warranty welding torches and their consumables are not covered Direct or indirect damage due to a defective product is not covered under the warranty The warranty is void if changes are made ...

Page 25: ...lternating current power sources with constant current output characteristics are normally employed to supply the welding current For DC operation the tungsten may be connected to either output terminal but is most often connected to the negative pole The output characteristics of the power source can have an effect on the quality of the welds produced Shielding gas is directed into the arc area b...

Page 26: ...elding speed A narrower deeper weld bead DCEP Wide bead shallow penetration Nozzle Ions Electrons The DCEP reverse polarity are different from the DCEN in following ways High heat is produced on the electrode rather on the base metal The heat melts the tungsten electrode tip The base metal remains relatively cool compared to using straight polarity Relatively shallow penetration is obtained An ele...

Page 27: ...mated welding Steel Argon Stable arc Good penetration Helium High speed automatic welding Deeper penetration Small concentrated HAZ Magnesium Alloys Argon Used with continuous high frequency AC Good arc stability Good cleaning action Stainless steel Argon Good penetration Good arc stability Helium Deeper penetration Titanium Argon Stable arc Helium High speed welding 15 5 Welding wire selection Th...

Page 28: ...s Good arc starts Medium tendency to spit Medium erosion rate 2 Ceriated EW Ce2 75 Argon 25 Helium Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Only thin sections Control penetration ACHF Zirconiated EW Zr Argon Use on lower currents only Spitting on starts Rapid erosion rates at higher currents Only thick sections Increase penetration or travel spe...

Page 29: ...e used when making a butt weld The torch is held 60 75 from the metal surface This is the same as holding the torch 15 30 from the vertical Take special note that the rod is in the shielding gas during the welding process 15 8 Torch movement during welding Tungsten Without Filler Rod Tungsten With Filler Rod Welding direction Form pool Welding direction Form pool 75 Tilt torch 75 Tilt torch Move t...

Page 30: ...d current ranges Thoriated ceriated and lanthanated tungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes and as such are typically used for DCSP welding These electrodes maintain a ground tip shape much better than the pure tungsten electrodes If used on AC thoriated and lanthanated electrodes often spit Regardless of the electrode tip geometry selected it is impor...

Page 31: ... BOC Smootharc TIG 200 ACDC Operating Manual Butt Weld and Stringer bead 90 20 70 T Joint 20 10 15 75 Corner Joint 90 15 75 Lap Joint 20 40 30 15 75 15 9 Positioning torch tungsten for various weld joints ...

Page 32: ...c TIG 200 ACDC Operating Manual 15 10 Joint preparation r s 2 s 2 3 0 S 2 3 0 3 4 12 2 10 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 Roll direction Offset All measurements in mm ...

Page 33: ...sity Air Air Oxides Oxides Long arc length Acute angle Loss of gas coverage Angular mis alignment Unsymmetrical bead profile Mis alignment Incomplete penetration Filler rod removed from gas shield Tungsten inclusions Tungsten inclusions Electrode contact with the weld pool Rod movement Oxides Air ...

Page 34: ...iece heating Only inert or reducing gases should be used for TIG welding and pure argon is normally recommended as the shielding gas for steel Filler rods are usually selected to match the chemical composition and the mechanical properties of the parent plate The weldability of the steel may impose restrictions on the choice of filler rod Steels with carbon contents above about 0 3 are hardenable ...

Page 35: ... 6 2 4 2 4 3 2 3 2 4 0 4 4 8 6 4 Gas flow l min 3 4 3 4 4 4 5 4 6 5 6 5 6 5 7 Current A 30 60 70 100 90 110 120 150 190 250 220 340 300 360 350 450 Consumable size mm 1 1 5 1 5 2 0 2 0 3 0 3 0 4 0 4 0 6 0 4 0 6 0 4 0 6 0 Polarity DC 16 4 Stainless steel TIG is a high quality process ideally suited for welding of stainless steels particularly thin sheet up to about 5mm thick where weld integrity an...

Page 36: ...output may be conventional sine wave or square wave and many electronic power sources allow the AC waveform to be adjusted and also provide facilities for pre and post gas flow and current slope in and slope out Aluminium welding parameters Plate Thickness mm 1 2 3 4 5 5 6 6 Joint type Square butt Square butt Square butt Square butt Square butt V butt 70 Square butt V butt 70 Tungsten size mm 1 6 ...

Page 37: ...per alloys particularly in thicker sections Pure argon is the shielding gas used for AC TIG welding TIG consumables are solid filler rods based on pure copper and several copper alloy compositions including aluminium bronzes silicon bronzes and cupro nickels It is normal to try to use a filler material with a similar composition to that of the parent material but this is not always possible and so...

Page 38: ...ly and is measured by the number of cycles completed per second The standard frequency of the AC supply in Australia is 50 Hz Hertz 17 2 Welding Machine The most important consideration when contemplating the use of arc welding for the first time is the purchase of a suitable welding machine BOC supplies a popular range of arc welding machines Machines range from small portable welders that operat...

Page 39: ...urfaces are not considered good make it the most attractive electrode of its class Continuous development and improvement of BOC Smootharc 13 has provided in built operating qualities which appeals to the beginner and experienced operator alike For further recommendations on the selection of electrodes for specific applications see table page 27 Electrodes and Typical Applications Name AWS Class A...

Page 40: ... to the correct terminal for the size electrode being used When using machines with adjustable current set on the current range specified The limits of this range should not normally be exceeded The following table shows the current ranges generally recommended for BOC Smootharc 13 Generally Recommended Current Range for BOC Smootharc 13 Size of Electrode mm Current Range Amp 2 5 60 95 3 2 110 130...

Page 41: ...t suit the application The following section describes the various joint types and areas of application 17 5 Types of Joints Butt Welds A butt weld is a weld made between two plates so as to give continuity of section Close attention must be paid to detail in a butt weld to ensure that the maximum strength of the weld is developed Failure to properly prepare the edges may lead to the production of...

Page 42: ...s The first run in a prepared butt weld should be deposited with an electrode not larger than 4 0 mm The angle of the electrode for the various runs in a butt weld is shown It is necessary to maintain the root gap by tacking at intervals or by other means as it will tend to close during welding All single V single U and square butt welds should have a backing run deposited on the underside of the ...

Page 43: ... fabrications where corrosion is likely to occur behind the lapped plates In applying fillet welds to lapped joints it is important that the amount of overlap of the plates be not less than five times the thickness of the thinner part Where it is required to preserve the outside face or contour of a structure one plate may be joggled Corner Joints The members are fitted as shown leaving a V shaped...

Page 44: ...llet Weld Data Nominal Fillet Size mm Minimum Throat Thickness mm Plate Thickness mm Electrode Size mm 5 0 3 5 5 0 6 3 3 2 6 3 4 5 6 3 12 4 0 8 0 5 5 8 0 12 over 4 0 10 0 7 0 10 over 4 0 Selection of welding current is important If it is too high the weld surface will be flattened and undercut accompanied by excessive spatter is likely to occur Alternatively a current which is too low will produce...

Page 45: ...weld of good profile Medium current is required for best results High current will cause undercutting and bad shape of the weld while low current will cause slag inclusions To produce a weld having good penetration and of good profile a short arc length is necessary Angle of electrode for overhead fillets is illustrated above 17 7 Typical Defects Due to Faulty Technique Manual metal arc welding li...

Page 46: ...incorrect electrode angles This defect can be prevented by choosing the proper welding current for the type and size of electrode and the welding position 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 Lack of Fusion ...

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Page 48: ...inting Whilst proper care has been taken in the preparation no liability for injury or damage resulting from its improper use can be accepted For more information contact the BOC Customer Engagement Centre on 131 262 AU or 0800 111 333 NZ BOC Limited ABN 95 000 029 729 10 Julius Avenue North Ryde NSW 2113 Australia www boc com au BOC Limited NZBN 94 290 4095 3946 970 988 Great South Road Penrose A...