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Linde BOC BOCTIG200DC, Operating Manual

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14

BOC Smootharc TIG 200 DC Operating Manual

Butt Weld and Stringer bead

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

‘T’ Joint

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

Corner Joint

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

Lap Joint

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

15°

75°

90°

20-40°

30°

15°

75°

90°

20°

70°

20°

10°

15°

75°

2.9   Positioning torch tungsten for various weld joints

2.7   Welding techniques 

TIG Welding techniques

 

60–75°

15–30°

Nozzle

Direction of travel

Welding Rod

Shield gas

Vertical

Tungsten electrode

The suggested electrode and welding rod angles for welding a bead on 

plate are shown above. The same angles are 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.

2.8   Torch movement during welding

Tungsten Without Filler Rod

Tungsten With Filler Rod

75°

75°

15°

Welding  

direction

 

Form pool

75°

75°

15°

Welding  

direction

 

Form pool

75°

75°

15°

 

Tilt torch

75°

75°

15°

 

Tilt torch

75°

75°

15°

 

Move torch to front of pool. Repeat.

75°

75°

15°

 

Add filler metal

75°

75°

15°

 

Remove rod

75°

75°

15°

 

Move torch to front of pool. Repeat.

Summary of Contents for BOC BOCTIG200DC

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

Page 2: ...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 own i...

Page 3: ...per and copper alloys 19 4 0 Manual Metal Arc Welding Process MMAW 20 4 1 Power 29 4 2 Shielding gas 29 4 3 TIG torch connection 29 4 4 MMA operation 29 4 5 TIG welding operation 29 5 0 Connections Package contents 29 6 0 Control panel and display 31 6 1 Control Panel 31 6 2 Display Panel symbols 32 7 0 Smootharc TIG 200 DC installation 33 7 1 Installation for TIG welding 33 7 2 Starting up 34 7 3...

Page 4: ...ipment 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 glov...

Page 5: ...ve 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 ve...

Page 6: ...ansit 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 end...

Page 7: ...ger 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 BOC s ext...

Page 8: ...ted 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 th...

Page 9: ...at 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 t...

Page 10: ...ility Intense heat means a larger diameter of electrode must be used with DCEP Maximum welding amperage should be relatively low approximately six times lower than with DCEN 2 1 Introduction The Tungsten Inert Gas or TIG process uses the heat generated by an electric arc struck between a non consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld p...

Page 11: ...ration 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 2 5 Welding wire selection The following table includes the recommended welding consumable for the most commonly welded materials Ba...

Page 12: ...Wide current range AC or DC No spitting Consistent arc starts Good stability Mild Steels Carbon Steels Alloy Steels Stainless Steels and Titanium alloys All General purpose DCSP 2 Thoriated EW Th2 75 Argon 25 Helium Best stability at medium currents 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 spitt...

Page 13: ... 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 import...

Page 14: ...s 60 75 15 30 Nozzle Direction of travel Welding Rod Shield gas Vertical Tungsten electrode The suggested electrode and welding rod angles for welding a bead on plate are shown above The same angles are 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 duri...

Page 15: ...5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 20 6 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1...

Page 16: ...ity 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 17: ...ce 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 an...

Page 18: ...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 6 1 6 2 0 2 0 3 2 3 2 4 0 4 0 6 0 4 0 6 0 4 0 6 0 Polarity DC 3 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 and ...

Page 19: ...er 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 som...

Page 20: ...e rate of change of direction of current flow is known as the frequency of the supply and is measured by the number of cycles completed per second The standard frequency of the AC supply in Australia is 50 Hz Hertz 4 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 ra...

Page 21: ...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 below Electrodes and Typical Applications Name AWS Class App...

Page 22: ...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 23: ... suit the application The following section describes the various joint types and areas of application 4 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 f...

Page 24: ...eral notes on Butt Welds 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 o...

Page 25: ...oided where possible and must never constitute the joints of tanks or other 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 ...

Page 26: ...let 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 27: ...ood 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 4 7 Typical Defects Due to Faulty Technique Manual metal arc welding like other w...

Page 28: ...correct 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 LA...

Page 29: ...IG The BOC AC DC TIG torch is fitted to the machine by means of the Safe Lock dinse back end For DC TIG operation fit the torch back end to the negative dinse connection Similarly for DC fit the torch back end to the positive dinse connection The gas hose is fitted to the gas fitting GAS located on the front bottom panel of the machine 4 4 MMA operation The Smootharc TIG 200 DC can be used as an M...

Page 30: ...nnect with TIG torch In MMA mode connect with work piece 3 Gas outlet Connect with TIG torch gas connector 4 Control socket Connect with TIG torch 5 Power switch Use this switch to supply single phase 240V 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 hose 8 F...

Page 31: ...tch the MMA and TIG mode MMA indicator When the MMA indicator light is on the machine is in the MMA mode TIG indicator When the TIG indicator light is on the machine is in the TIG mode 95 6 7 7 3 Menu button MMA mode Long press 3s Open close the VRD function Short press switch the hot start current hot start time and force current TIG mode Long press 3s switch the 2T HF 4T HF spot HF and 2T LIFT m...

Page 32: ...bol lights up 95 6 7 7 3 Spot mode The machine is in spot mode when this symbol lights up Set spot time parameter range is 0 1 9 9s 95 6 7 7 3 Hot start current Hot start time Set the hot start current and hot start time under MMA mode Hot start current 0 50 Hot start time 0 2 s Pulse frequency Pulse width Set the pulse frequency and pulse width under TIG mode Pulse frequency 0 200 Hz Pulse width ...

Page 33: ...connector of TIG torch to welding machine s gas and electric socket and tighten firmly 5 Connect gas regulator to gas cylinder 6 Connect one end of gas hose to gas outlet of gas regulator Fasten the hose clamp Connect the other end to gas inlet on rear panel of welding machine 7 Connect with single phase 240V power supply Turn power switch ON switch is located on the back of the welding machine 7 ...

Page 34: ...oose 2T LIFT 2T HF 4T HF Spot HF mode Under the TIG welding mode there are four modes 2T LIFT 2T HF 4T HF and Spot HF Press the welding menu buttonn for 3 seconds and then release to choose the mode as shown in figures 1 4 1 2T LIFT mode 3 4T HF mode 2 2T HF mode 4 Spot HF mode 7 95 6 7 7 3 6 7 95 6 7 7 3 6 7 95 6 7 7 3 6 7 95 6 7 7 3 6 IMPORTANT Before you begin a welding operation please press t...

Page 35: ...ct the parameters Figures 5 14 to be set by pressing the welding menu button and then adjusting the parameter value using the Adjustment Knob The Start Current Figure 6 and Up slope time Figure 7 are invalid under 2T HF mode The spot welding time Figure 11 is only used in spot HF mode NOTE If welding does not commence after 5 seconds the machine will revert back to its default setting See Figures ...

Page 36: ... that the MMA TIG selector switch is in the TIG position For DC Pulse TIG welding DC welding of thin material can further be enhanced by using the pulse mode When using the pulse mode for DC applications the current will be varied between the welding current and a pre selected background current Additionally the pulse frequency can be adjusted By adjusting the pulse frequency the optimum heat inpu...

Page 37: ...nce between the tungsten and the work piece Press the torch switch to start welding LIFT Touch the tungsten to the workpiece Press the torch switch to start welding There may be a delay to the arc initiation depending on your pre gas setting When welding stops trigger is released hold your torch postion over the weld pool to allow a good finish 7 95 6 7 7 3 6 7 95 6 7 7 3 6 7 95 6 7 7 3 6 7 95 6 7...

Page 38: ... 3RVW JDV 3UHVV 5HOHDVH RZQ VORSH RZQ VORSH RZQ VORSH RZQ VORSH RZQ VORSH RZQ VORSH RZQ VORSH RZQ VORSH 8S VORSH 8S VORSH 8S VORSH 8S VORSH 8S VORSH 8S VORSH 3UHVV 5HOHDVH 3UHVV 5HOHDVH 3UHVV 5HOHDVH 3UHVV 5HOHDVH XUUHQW FWLRQ 7 6ZLWFK DV XUUHQW FWLRQ 7 6ZLWFK DV XUUHQW FWLRQ 7 6ZLWFK DV XUUHQW 2T LIFT mode 4T HF mode 2T HF mode Spot HF mode 7 7 TIG weld initiation and termination stages ...

Page 39: ... power supply Turn power switch ON switch is located on the back of the welding machine 5 Press the bottom left button to select function MMA 6 Press the top left button to select welding mode AC DC on MMA mode On DC mode ARC starting ARC force and Current are adjustable Rotate parameter selection knob to choose these parameters Rotate parameter adjustment knob to adjust these parameters 7 Rotate ...

Page 40: ... VRD function Under the MMA mode press the menu button for 3 seconds and then release to initiate Figure 15 or turn off Figure 16 the VRD function Adjusting parameters Under the MMA mode select the parameters Figures 17 20 by pressing the menu button and then adjusting the parameter value using the adjustment knob NOTE If welding does not commence after 5 seconds the machine will revert back to de...

Page 41: ...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 9 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 wit...

Page 42: ...nal fault 1 Replace the fan 2 If problem persists please contact a service agent 4 1 Press the TIG torch switch It has no gas output but has current output 1 The gas solenoid is broken 2 The gas hose is blocked 1 Check the gas hose 2 If problem persists please contact a service agent 5 1 Press the TIG torch switch it has no gas or current output 1 The torch switch is broken or has poor connection ...

Page 43: ...liance with operating and maintenance instructions such as connection to incorrect faulty voltage supply including voltage surges outside equipment specs and incorrect overloading Natural wear and tear and accidental damage Transport or storage damage The Warranty is void if Changes are made to the product without the approval of the manufacturer Repairs are carried out using non approved spare pa...

Page 44: ...ated input current I1max 27A 28A Maximum effective supply current I1eff 13 5A 14A No load voltage 58V Output current 15 200A 30 160A Rated working voltage 18V 26 4V Duty cycle 25 200A 160A 60 130A 103A 100 100A 80A Arc initiation HF Lift Efficiency 80 Power factor 0 73 Insulation grade F Housing protection grade IP21S Weight 5 6kg Dimensions L W H 315 145 250mm Standards AS NZS 60974 1 IEC EN 6097...

Page 45: ...45 BOC Smootharc TIG 200 DC Operating Manual ...

Page 46: ...46 BOC Smootharc TIG 200 DC Operating Manual ...

Page 47: ......

Page 48: ...e 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 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 WN007748 970 988 Great South Road Penrose Aucklan...

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