MIG 225C & 255C
Operating Manual
Страница 1: ...MIG 225C 255C Operating Manual...
Страница 2: ...ibility 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 a...
Страница 3: ...TIG 24 7 3 Operation instruction of MMA 24 8 0 Periodic Maintenance Troubleshooting 25 8 1 Power Source Maintenance 25 8 2 Fault Troubleshooting 25 9 0 Warranty Information 26 9 1 Terms of Warranty 2...
Страница 4: ...ng equipment 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 s...
Страница 5: ...lways have 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...
Страница 6: ...u 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...
Страница 7: ...ified 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 immedi...
Страница 8: ...t I1 Rated 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...
Страница 9: ...ines that 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 p...
Страница 10: ...0 8 1 0 0 9 1 0 Gas hose 3m Belt cylinder restraint Optional Extra TIG torch 4m Part No MMA TIG MIG 255C Package Contents Power source with 15A input cable and plug fitted for demonstration and 32A i...
Страница 11: ...255 180 160 U2 V 25 3 19 7 18 4 19 15 2 14 29 23 7 22 8 26 8 24 23 20 2 18 17 2 30 2 27 2 26 4 Output Current Range A 53 225 20 225 20 225 53 255 20 255 20 255 Output Voltage Range V 16 7 25 3 10 8 19...
Страница 12: ...1 4 3 6 5 2 1 MIG Torch socket 2 Positive terminal 3 Negative terminal 4 Short mechanical connector pigtail 5 Power cable 6 Power switch 7 Gas inlet IMPORTANT The 225C and 255C machines come fitted wi...
Страница 13: ...ove for use with soft wires such as aluminium Knurled rollers for flux cored wire 5 Release top pressure roller assemblies and insert the wire Re fit and tension rollers ensuring the wire is gripped s...
Страница 14: ...Part No MMA TIG 5 3 Installation for MMA process 1 Connect the electrode holder to the positive terminal 2 of the machine and fasten it clockwise tightly DCEP 2 Connect the work return lead into the n...
Страница 15: ...screen Long press 5 seconds the right knob to enter the Service screen Wire Inch Button Press and hold the Wire Inch Button on the power source or wire feeder panel to start wire inch Release the but...
Страница 16: ...ions Including JOB0 JOB9 JOB0 means no stored data JOB1 JOB9 can store data If there is no data stored in JOB1 JOB9 it cannot be selected 6 3 Welding parameter Icons Icon Description Inductance Range...
Страница 17: ...orage dialog box 1 Rotate left knob to set the welding current and plate thickness and the voltage will match automatically 2 Short press right knob to switch welding voltage inductance L 3 Rotate rig...
Страница 18: ...ime Synergic 2TS 4S modes only Spot time Range 0 5 to 5 sec 2TS Screen 4S Screen Spot Screen 1 Rotate Left knob to switch parameter options 2 Rotate Right knob to set the parameter value 3 Short press...
Страница 19: ...gger again L 1 Long press 5 seconds the left knob to pop up the SELECT JOB dialog box 2 Rotate right knob to switch JOB number 3 Press left knob to pop up the SAVE dialog box 4 Rotate right knob to se...
Страница 20: ...h left knob rotate right knob select Main SET and then press right knob to enter the MIG SYN welding screen In the MIG SYN welding screen long press 5s right knob to enter the Service Screen as shown...
Страница 21: ...n to STOP the wire inch The LCD screen displays INCH and flashes continuously as shown in the figure below Gas Test Screen Inch Screen 6 11 Gas Test Screen 6 12 Inch Screen 6 13 Aluminium Welding Addi...
Страница 22: ...Rotate the left knob to adjust welding current short press right knob to switch to voltage and inductance and rotate right knob to set welding voltage or inductance Note In the Main Settings please re...
Страница 23: ...nversely on thinner sections less inductance would lead to a decrease in arc on time and consequently a cooler arc which enables thin materials to be welded with ease Summarising inductance has the fo...
Страница 24: ...welding After setting the welding operation can be carried out When welding the display screen shows real time current and voltage 7 3 Operation instruction of MMA 1 Starting up Turn the power switch...
Страница 25: ...sure washing devices Do not use compressed air as pressure may pack dirt even more tightly into components Only authorised electricians should carry out repairs and internal servicing 8 2 Fault Troubl...
Страница 26: ...enses loss damage of costs including but not limited to daily allowances or accommodation and travelling costs NOTE Under the terms of warranty welding torches and their consumables feed drive rollers...
Страница 27: ...ored continuous electrode and carbon dioxide shielding gas or using self shielding flux cored wire requiring no shielding gas 10 2 Introduction to Flux Cored Arc Welding FCAW How it Works Flux cored a...
Страница 28: ...istance increases if the voltage remains stable then the current must fall To bring the welding current back to 250 amps it is necessary to increase the wire feed speed effectively increasing the amou...
Страница 29: ...n on either The work return lead is then connected to the opposite terminal Electrode negative operation will usually give better positional welding characteristics The output characteristics of the p...
Страница 30: ...nsfer mode is used for all positional work with these types of wire Globular Transfer Metal transfer is controlled by slow ejection resulting in large irregularly shaped globs falling into the weld po...
Страница 31: ...le 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 for positional welding too Basic flux cored and self sh...
Страница 32: ...n the liners If the helix is too large the wire will leave the tip with a corkscrew effect Selection of the Correct Power Source Power sources for MIG welding is selected on a number of different crit...
Страница 33: ...at has to be selected As a general rule the thicker the material C Mn and Alloy steels are the higher the percentage of CO2 in the shielding gas mixture Different grades of shielding are required for...
Страница 34: ...t or alternating 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...
Страница 35: ...r welding Carbon steels Stainless steels Copper alloys The increased amperage provides Deeper penetration Increased welding speed A narrower deeper weld bead DCEP Wide bead shallow penetration Nozzle...
Страница 36: ...ium 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 Stabl...
Страница 37: ...s 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 s...
Страница 38: ...iated 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...
Страница 39: ...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 11 8 Torch movement during welding Tungsten Without Fil...
Страница 40: ...5 75 Corner Joint 15 75 90 20 40 15 75 90 20 7 20 10 15 75 15 75 90 20 40 15 75 90 20 70 20 10 15 75 90 20 40 30 90 20 10 Lap Joint 90 20 30 2 10 15 75 90 20 40 30 15 7 90 20 20 10 15 75 15 75 90 20 4...
Страница 41: ...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 2...
Страница 42: ...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...
Страница 43: ...eted per second The standard frequency of the AC supply in Australia is 50 Hz Hertz 12 2 Welding Machine The most important consideration when contemplating the use of arc welding for the first time i...
Страница 44: ...13 electrodes will handle virtually all applications BOC Smootharc 13 is suitable for welding mild steel in all positions using AC or DC power sources Its easy striking characteristics and the toleran...
Страница 45: ...the electrode or producing a rough spattered surface i e the current in the middle of the range specified on the electrode package is considered to be the optimum In the case of welding machines with...
Страница 46: ...the cut offs flame cutting and others In all cases edges should be prepared for the joints that suit the application The following section describes the various joint types and areas of application 12...
Страница 47: ...ly 15 and the upper member 45 making an included angle of 60 This preparation provides a ledge on the lower member which tends to retain the molten metal General notes on Butt Welds The first run in a...
Страница 48: ...a structure one plate may be joggled Corner Joints The members are fitted as shown leaving a V shaped groove in which a fillet weld is deposited Fusion should be complete for the full thickness of the...
Страница 49: ...h should be attempted with one pass of a large electrode is 8 0 mm Efforts to obtain larger leg lengths usually result in collapse of the metal at the vertical plate and serious undercutting For large...
Страница 50: ...ity of the weld are arc blow finger nailing and improper electrode coating moisture contents Defects caused by welding technique Slag Inclusions Slag inclusions occur when slag particles are trapped i...
Страница 51: ...or between passes in a multiple pass weld Causes of this defect can be excessive travel speed electrode size too large welding current too low poor joint preparation letting the weld metal get ahead o...
Страница 52: ...ickness 3mm 6mm 10mm 6mm 8mm 12mm Welding position all all all horizontal horizontal horizontal Wire diameter mm 0 9 0 9 0 9 0 9 1 2 1 2 Wire feed speed m min 8 10 11 13 12 14 12 14 8 10 9 11 Voltage...
Страница 53: ...ed m min 5 7 8 10 6 8 8 10 8 10 10 12 Voltage volts 14 16 16 18 16 18 21 23 21 23 23 25 Current amps 50 70 90 120 160 200 190 240 190 240 240 280 Gas flow rate l min 15 15 15 15 15 15 13 4 Aluminium S...
Страница 54: ...with cored wires takes place normally with the drag technique The welding torch is tilted at an angle of 10 away from the direction of welding For all other applications the torch angle remains the sa...
Страница 55: ...nce on the weldbead profile Influence of the change in electrical stickout length on the weldbead profile The travel speed will have an influence on the weldbead profile and the reinforcement height I...
Страница 56: ...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...
