Linde BOC Smootharc Advance II MIG 250R User manual

MIG 250R
Operating manual
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Machine comes with side tray

2BOC Smootharc Advance II MIG 250R 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 machine.
With normal use and by following these recommended steps, your
Smootharc ADVANCE machine can provide you with years of trouble-
free service. Smootharc ADVANCE equipment and technical support is
available through the national BOC Customer Service Centre or contact
your local Gas & Gearoutlet.
Please Note: This machine is to be used only by appropriately trained
operators in industrial applications.
Important Notice
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 specic 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.
Neither BOC nor any of its agents has independently veried the accuracy of the information contained in this
document. The information in this document is commercial in condence and is not to be reproduced. The recipient
acknowledges and agrees that it must make its own independent investigation and should consider seeking appropriate
professional recommendation in reviewing and evaluating the information. This document does not take into account
the particular circumstances of the recipient and the recipient should not rely on this document in making any decisions,
including but not limited to business, safety or other operations decisions. Except insofar as liability under any statute
cannot be excluded, BOC and its a󹠣liates, directors, employees, contractors and consultants do not accept any liability
(whether arising in contract, tort or otherwise) for any error or omission in this document or for any resulting loss or
damage (whether direct, indirect, consequential or otherwise) su󹠢ered by the recipient of this document or any other
person relying on the information contained herein. The recipient agrees that it shall not seek to sue or hold BOC or
their respective agents liable in any such respect for the provision of this document or any other information.

3BOC Smootharc Advance II MIG 250R Operating manual
Contents.
1.0 Recommended Safety Guidelines andPrecautions 4
1.1 Health Hazard Information 5
1.2 Personal Protection 5
1.3 Electrical shock 6
1.4 User Responsibility 6
Switch on to electrical safety 8
2.0 Package Contents 10
3.0 Technical Specications 11
4.0 Installation 12
4.1 Installation for MIG/MAG process 12
4.2 Installation for MMA process 13
5.0 Control panels 14
5.1 Control Panel Features 14
5.2 Inductance 15
5.3 Synergic Control (One Knob Control) 15
5.4 4T/2T Trigger Latch Selection 15
6.0 Operation Setup 16
6.1 MIG Welding Setup 16
6.2 MMA Welding Setup 16
7.0 Troubleshooting and Fault Finding 17
8.0 Replacement Parts 18
9.0 Periodic Maintenance 19
9.1 Power Source 19
10.0 Warranty Information 20
10.1 Terms of Warranty 20
10.2 Limitations on Warranty 20
10.3 Warranty Period 20
10.4 Warranty Repairs 20
11.0 MIG Process 21
11.1 Introduction to Metal Inert Gas (MIG) 21
11.2 Introduction to Flux Cored Arc Welding (FCAW) 21
11.3 Introduction to Metal Cored Arc Welding (MCAW) 23
11.4 Fundamentals of MIG, FCAW and MCAW 26
12.0 MMA Process 28
12.1 Process 28
12.2 Welding Machine 28
12.3 Welding Technique 29
12.4 Electrode Selection 29
12.5 Types of Joints 31
12.6 Fillet Welds 33
12.7 Typical Defects Due to FaultyTechnique 35
13.0 General Welding Information 37
13.1 Recommended Welding Parameters 37
14.0 Correct Application Techniques 39

4BOC Smootharc Advance II MIG 250R Operating manual
1.0 Recommended Safety Guidelines
andPrecautions
Some safety precautions BOC
recommends are as follows:
→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.
→Leads and cables should be kept clear of passageways.
→Keep fire extinguishing 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 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 gloves
Insulate yourself from work and ground
Disconnect input power before working on equipment
Keep head out of fumes
Use forced ventilation or local exhaust to remove fumes
Use welding helmet with correct shade of lter

5BOC Smootharc Advance II MIG 250R 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.
Skin
Arc rays are dangerous to uncovered skin.
Inhalation
Welding fumes and gases are dangerous to the health of the operator
and to those in close proximity. The aggravation of pre-existing
respiratory or allergic conditions may occur in some workers. Excessive
exposure may cause conditions such as nausea, dizziness, dryness and
irritation of eyes, nose and throat.
1.2 Personal Protection
Respiratory
Confined space welding should be carried out with the aid of a fume
respirator or air supplied respirator as per AS/NZS 1715 and AS/NZS
1716 Standards.
→You must always 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 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 ventilation is not sufficient.
Eye protection
A welding helmet with the appropriate welding filter lens for the
operation must be worn at all times in the work environment. The
welding arc and the reflecting arc flash gives out ultraviolet and infrared
rays. Protective welding screen and goggles should be provided for
others working in the same area.
Recommended filter shades for arc welding
Less than 150 amps Shade 10*
150 to 250 amps Shade 11*
250 to 300 amps Shade 12
300 to 350 amps Shade 13
Over 350 amps Shade 14
*Use one shade darker for aluminium.
Clothing
Suitable clothing must be worn to prevent excessive exposure to UV
radiation and sparks. An adjustable helmet, flameproof loose-fitting
cotton clothing buttoned to the neck, protective leather gloves, spats,
apron and steel capped safety boots are highly recommended.

6BOC Smootharc Advance II MIG 250R Operating manual
Cylinder safety diagram
1Cylinder valve hand-wheel
2Back-plug
3Bursting disc
Ten points about cylinder safety
1Read labels and Safety Data Sheet (SDS) before use
2Store upright and use in well ventilated, secure areas away
from pedestrian or vehicle thoroughfare
3Guard cylinders against being knocked violently or being
allowed to fall
4Wear safety shoes, glasses and gloves when handling and
connecting cylinders
5Always move cylinders securely with an appropriate trolley.
Take care not to turn the valve on when moving a cylinder
6Keep in a cool, well ventilated area, away from heat sources,
sources of ignition and combustible materials, especially
flammable gases
7Keep full and empty cylinders separate
8Keep ammonia-based leak detection solutions, oil and grease
away from cylinders and valves
9Never use force when opening or closing valves
10 Don’t repaint or disguise markings and damage. If damaged,
return cylinders to BOC immediately
Cylinder valve safety
When working with cylinders or operating cylinder valves, ensure
that you wear appropriate protective clothing – gloves, boots and
safetyglasses.
When moving cylinders, ensure that the valve is not accidentally opened
in transit.
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 ends.
Stand to the side of the cylinder so that neither you nor anyone else is
in line with the back of the cylinder valve. This is in case a back-plug
is loose or a bursting disc vents. The correct stance is shown in the
diagramabove.
When operating the cylinder valve
Open it by hand by turning the valve hand-wheel anti-clockwise. Use
only reasonable force.
Ensure that no gas is leaking from the cylinder valve connection or
the system to which the cylinder is connected. 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. Use only
reasonable force.
Remember NEVER tamper with the valve.
If you suspect the valve is damaged, DONOT use it. Report the issue to
BOC and arrange for the cylinder to be returned to BOC.
Back view of typical cylinder valve.
1
2
3
Operator wearing personal
protective equipment (PPE)
in safe position.

7BOC Smootharc Advance II MIG 250R Operating manual
1.3 Electrical shock
→Never touch ‘live’ electrical parts
→Always repair or replace worn or damagedparts
→Disconnect power source before performingany maintenance
orservice
→Earth all work materials
→Never work in moist or damp areas
Avoid electric shock by:
→Wearing dry insulated boots.
→Wearing dry leather gloves.
→Working on a dry insulated floor where possible.
1.4 User Responsibility
→Read the Operating Manual prior to installation of this machine.
→Unauthorised repairs to this equipment 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 BOC’s extensive Gas and Gear network ensures fast, reliable service
throughout the South Pacific.
STOP
PLEASE NOTE that under no circumstances should any
equipment or parts be altered or changed in any way from
the standard specification without written permission given
byBOC. To do so will void the EquipmentWarranty.
Further information can be obtained from Welding Institute of Australia
(WTIA) Technical Note No.7.
Health and Safety Welding
Published by WTIA,
PO Box 6165 Silverwater NSW 2128
Phone [phone]

8BOC Smootharc Advance II MIG 250R Operating manual
Switch on to electrical safety
Switch on to
electrical safety
for single-phase equipment
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BOC welding machines are designed and manufactured to
conform to IEC60974 or AS 60974. This Standard not only covers
themachine but also the input cable and plug requirements
including the size of theplug that should be used.
X
Rated duty cycle
I0
Rated no-load
supply current
I1
Rated
supply current
AS60974-1
Formula in clause 3.33
Maximum effective supply current
I1eff = √I12× X + I02(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 – 4 mm2
25A 2.5–6mm2
32A 4 – 10 mm 2
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).
Remember…

9BOC Smootharc Advance II MIG 250R Operating manual
DO
Always
DON‘T Example of BOC rating plate
How important is the correct input cable and plug on a welding machine?
The size of the plug depends on a formula that
not only uses the maximum current draw but
also the duty cycle of the power source. Theuse
of any welding power source will not only cause
the machine itself to heat up, but the input
cable, plug and mains power circuit will increase
in temperature as well. That’s why it’s important
to understand input and output currents and to
make sure that the input circuit is correctly rated
to supply the required input draw. Thisallows
the machine to operate at or near maximum
output and protects the circuit board from
tripping, overheating and/or catchingfire.
For your safety, BOC meets AS/NZS Standards for safe electricalcompliance.
All BOC welding machines undergo an
independent certification process to meet
Australian and New Zealand regulations
regarding electrical safety. The triangle-
circle-tick (RCM) symbol signifies that BOC
has taken the necessary steps to have the
product comply with the electrical safety
and/or electromagnetic compatibility (EMC)
legislative requirements as specified by the
Electrical Regulatory Authorities Council
(ERAC). Depending on the machine, BOC may
be required to have a 32A single phase plug
to ensure that when the machine runs at its
maximum output, the input supply plug and
lead will not overheat. For your safety, please
check for this symbol before buying any welding
machine in Australia and NewZealand.
Check the rating plate onyourmachine.
All welding machines that comply with IEC 60974
or AS 60974 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 the minimum capacity of the
input circuit that the machine gets plugged
into to safely operate the machine. Look for the
I1eff on the welding machine’s rating plate and
ensure that you have the correct input circuit to
support this powerdraw.
What if I don’t have a 240 volt 15 amp or 32 ampoutlet?
If you don’t have a suitable power outlet, you
should contact a qualified electrician to advise
whether the wiring in your building will cater for
a 15 amp or 32 amp outlet. You mayalso need
to upgrade your circuit breakers and possibly
switchboard to suit. Failure to do this may cause
an electrical fire in the building which may
voidinsurances.
Regulatory Compliance Mark (RCM)
andnumber
✓Use the correct input current,
✓cable and ✓ plug in accordance
with AS60974-1 for your safety and
to get the maximum performance
from your welding machine.
Example
If the I1eff rating on your
machine is 27A then you must
use a 32A plug as a 15A is
undersized for the welding
current being used and may
cause the cable to overheat.
✖Don’t risk damage to your
machine or cause tripping and/
or fire by using the wrong input
current, cable orplug.
✖Don’t tamper with plugs or
filedown earth pins. Doing so
willvoidwarranty.
✓ Inspect cables and plugs
regularly. ✓Contact a qualified
electrician for advice and/or
upgrade and, if needed, to replace
any damaged plugs orcables.
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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).

10 BOC Smootharc Advance II MIG 250R Operating manual
2.0 Package Contents
Package Contents
Power source with input cable
MIG Torch Binzel MB 24KD
BOC Argon regulator
Work return lead
Wire feeder
Interconnecting cable for wire feeder
(10 m)
Wire feed rollers
Knurled 0.8-0.9/1.0-1.2
U Groove 0.8-0.9/1.0-1.2
V Groove 0.6-0.8/0.9-1.0/1.0-1.2
Toolbox
Torch holder
MMA Electrode holder

11BOC Smootharc Advance II MIG 250R Operating manual
3.0 Technical Specications
Specifications MIG/MAG MMA
Part No. ADVANCE II250R-1
Input voltage Single phase 240V ±15%
Frequency 50/60 Hz
Maximum rated input current (I1max)46A 44 A
Maximum effective supply current (I1eff)27.2 A 24.1A
Output current 50–250A 50 –220 A
Output voltage 16.5–26.5V 22–28.8 V
Duty cycle
30 % –220A
35 % 250A –
60 % 200A 180A
Power factor 0.73
Efficiency 80 %
Wire feeder Remote
Wire speed 2–15 m/min
Wire spool diameter 270mm
Wire diameter 0.8/1.0 mm
Housing shielding grade IP21
Insulation grade F
Dimensions L×W × H 970×458 × 1196mm
(Power source with trolley and wire feeder)
Weight approx. 44 kg (Power source with trolley)
Weight approx. 12.6kg (Wire feeder)
Standards AS/NZS 60974-1, IEC/EN 60974-10

12 BOC Smootharc Advance II MIG 250R Operating manual
4.0 Installation
Installation for MIG/MAG process
IMPORTANT
This machine comes fitted with a 32A rated single phase plug
for compliance to AS/NZ electrical regulations.
4.1 Installation for MIG/MAG process
1 Connect the gas cylinder to the regulator. Select correct shielding gas
for the application.
2 Insert the earth return lead connection into the front panel.
3 Fit the wire spool to the machine. Select correct welding wire for
application.
4 Select the appropriate feed roller to suit the wire being used
- This machine comes complete with three types of wire feed rollers
- V groove for use with solid carbon manganese and stainless steels
- U groove for use with soft wires such as aluminium
- Knurled to be used with flux cored wires
5 Loosen the wire feed tension screws and insert the wire. Re fit and
tension rollers ensuring the wire is gripped sufficiently so as not
to slip but avoid over tightening as this can affect feed quality and
cause wire feed components to wear rapidly.
6 Fit and tighten the torch on the output connection. Ensure correct
torch liner and contact tip are selected.
7 Polarity selection can be reversed when welding in MIG/MAG mode.
This is important for certain types of self-shielded flux cored wires.
This can be achieved by switching the work return lead to the positive
(+) terminal and the short mechanical connector (link plug) to the
negative (-) terminal for a DC electrode negative polaritysetting.
Primary current rating
This machines has a maximum primary current input (I1max) rating of
46amps. Toobtain full rated output, they must be:
a) connected to an approved plug and socket or
b) direct wired to an electrical circuit rated and protected for at
least32amps.
Consult an electrician for any additional wiring requirements.
Effective primary current
The effective primary current (I1eff) based on the calculation from
AS/NZS 60974.1 welding power sources is 27.2A.
Start-up Current
Due to the design of the welding power source, a high start up (inrush)
current will occur in the primary circuit when initially energised, in the
case of a MIG welder this happens when the torch trigger is pressed.
In some cases this inrush current can cause the electrical supply circuit
breaker to trip. The occurrence of this happening will vary depending
on the size and type of circuit breaker installed, and the output settings
of the welder. To overcome this problem, a “D” curve circuit breaker can
be installed which is designed to delay its tripping time to allow for the
high start-up current of motors and transformers. Consult an electrician
for more information on circuit breaker selection.
WARNING
All electrical work must be carried out by a qualifiedelectrician.

13BOC Smootharc Advance II MIG 250R Operating manual
Installation for MMA process
4.2 Installation for MMA process
1 Connect the electrode holder to the positive (+) 6 of the machine and
fasten it clockwise tightly.
2 Connect the work return lead into the negative (-) 8of the machine
and fasten it clockwise.
3 Please note that for manual metal arc (MMA) welding the electrode
holder can be switched to the negative pole of the welding machine
if so required by the specification of the electrode.
4 The short mechanical connector (link plug) 7should remain
hangingfree.
68
7

14 BOC Smootharc Advance II MIG 250R Operating manual
5.1 Control Panel Features
The easy-to-operate and understand machine front panel includes two
LED displays for welding voltage and current/wire feed speed.
Torch latching
This is obtained by using the scroll button on the machine front face.
Wire feed motor speed range adjustment
The operating parameters of the wire feed motor can be altered by
switching to low or high speed range using the scroll button on the front
panel of the machine.
Gas Purge
The gas purge allows setting of the gas flow rate without the wire
feeding through the wire feed unit. This can also be used to purge the
system prior to the start of welding or after shutdown to ensure that no
shielding gas is trapped within the system.
Remote Wire feed front panel
The controls situated on the wire feeder allows the operator full
control over the welding parameters without having to go back to the
powersource.
Wire inch control
This control will feed the wire at a rate of 11m per minute through the
wire feeder without activating the gas solenoid of the power source
eliminating wastage of shielding gas.
By holding the button down it enables the operator to inch the wire
through the torch without having to depress the trigger.
This is also a safety feature because, if the operator uses the trigger on
the torch to feed the wire through, the welding current will also be on.
When the wire exits the torch it may make contact with the work piece
and cause an arc flash. This is injurious to exposed eyes and skin. It also
allows the wire to be feed through without the shielding.
Voltage adjustment
The inverter power source allows infinite adjustment of welding voltage
even when the arc is struck.
Wire speed/amperage
The wire feed control adjusts the speed that the wire is fed through the
MIG torch. The BOC Smootharc Advance wire feed control is stepless
which means it can be adjusted whilst welding. This is an excellent
feature with these machines because the operator can set the ideal
parameters when welding. The higher the wire feed speed the higher
the amperage of the machine.
Inductance
Refer to page 15 for a complete explanation of the function of
inductance. Inductance on the BOC Smootharc Advance machine can
infinitely be adjusted.
Changing the inductance will have an enhancing effect on both spatter
and weld bead appearance during dip transfer. Virtually spatter free
welds can be obtained even when using 100% CO2as a shielding gas.
Control panel of wire feeder
5.0 Control panels
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Current meter/
Wire speed meter
Control panel of MIG 250R
4 Wire speed/Arc current knob
5 Voltage Knob
2 Process selection switch
Voltage meter
9 Power indicator light
1 2T/4T button
3 Inductance Knob
17 Wire inch button
18 Voltage adjustment
15 Wire speed
adjustment

15BOC Smootharc Advance II MIG 250R Operating manual
5.2 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”. This short-circuit causes the current to rise
rapidly and burn off the wire violently. This rapid melt flings about metal
globules as it takes place. These globules settle on the work-piece and
welding torch in the form of “spatter”.
To control the rise rate of short-circuiting current, a choke (or inductor) is
fitted in series with the welding power cable. This inductor “chokes” the
rate of rise of current and ensures a smooth arc condition.
Inductance controls the rate of rise of short-circuiting current. It becomes
evident that inductance must be a function of time and current, since it
controls the time taken for the current to rise to the pre-set value. Hence
an increase in inductance results in less frequent short-circuiting. Fewer
short-circuits imply that the arc is present for a longer duration of time.
Increased “arc-on” time means increased heat.
Therefore, on a heavier plate where more heat is required to ensure
good fusion, more inductance would contribute immensely. Conversely
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 following effects:
→reduced spatter
→heat control
→has no effect when spray-arc welding, because there is no more
change in current, the inductance coil plays no further part. A certain
amount of inductance with spray-transfer will provide softer starts
(the initial short-circuit)
5.3 Synergic Control (One Knob Control)
In synergic control the machine will automatically select the voltage and
wire feed speed to be in balance depending on the curve that has been
selected for that application. For example, if the voltage is changed the
wire speed will be automatically adjusted for the selected voltage.
Most power sources will allow fine adjustment for individual welding
preferences.
5.4 4T/2T Trigger Latch Selection
On all MIG machines there is no current or wire feed until the trigger
on the torch is depressed. If a welder is doing a lot of welding then he
has to hold the trigger down for long periods of time and may cause
discomfort. This can be similar to repetitive strain injury (RSI) that has
become a very popular topic for compensation by office workers.
On all machines a special function called 2T and 4T is available. Also
referred to as trigger latching, this special feature allows the operator to
relax the trigger after first depressing it, the gas shielding to start before
the welding commences. This feature is of particular importance as it
ensures that the weld will have adequate gas shielding to eliminate the
risk of oxidisation (contaminants) causing a defective weld. Adefective
weld may not be detected by a visual inspection.
The 2T/4T function also allows for the shielding gas to continue after the
weld has finished and cooled. This eliminates the risk of oxidation while
the weld is still in its molten state. This is particularly important when
welding stainless steel materials.

16 BOC Smootharc Advance II MIG 250R Operating manual
6.1 MIG Welding Setup
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 is in place
4 Switch machine on using On/Off switch 12 at the back of the
machine
5 Open gas cylinder and set gas flow rate
6 The REM indicator light goes on when the power source and wire
feeder are connected. This means the wire speed feed 15 and
voltage 18 will need to be adjusted on the wire feeder control panel
7 Set voltage and wire feed speed (the tables included in this manual
can be used as a guideline for voltage and wire speed selection)
8 Voltage is set by adjusting voltage knob 18 on wire feeder
9 Inductance can be changed by adjusting the 3 on the power
source. The value will be displayed on the power source control panel
while welding
10 Welding wire can be fed through the torch by selecting the “Wire
Inch” button 17 on the wire feeder
11 For certain types of self shielded flux cored wires it is required to
change the polarity. This can be achieved by switching the work
return lead and clamp from the negative dinse connector8to the
positive dinse connector 6. The pigtail needs to then change from the
positive dinse connector 6 to the negative dinse connector8.
NOTE
Refer to the Control Panels section for a complete explanation of
allfunctionalities.
6.2 MMA Welding Setup
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 is in place
4 Fit work return lead to negative dinse* 8
5 Fit electrode holder to positive dinse connector* 6
6 Switch machine on using On/Off switch 12 at the back of
themachine
7 Select process by depressing the process selection switch 2 toMMA
8 Select amperage by turning by wire feed speed/Arc current knob4
*
DCEP Connection. For DCEN when recommended by the
consumable supplier, reverse the terminals as stated in
points4 & 5.
6.0 Operation Setup
Front and back of power source Front and back of wire feeder
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21
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14
13
12
109
8
7
6
543
2
1
11
18
19
17
20
16
15
21
1 2T/4T switch
2Process selection
3 Inductance adjustment
4 Current/wire speed adjustment
5 Voltage adjustment
6Positive terminal
7Polarity switch connector
8 Negative terminal
9 Thermal protection/fault indicator
10 REM (Remote Equipment Activation)
11 Primary power connection
12 Power switch
13 Wire feeder control connection
14 Wire feeder mechanical connection
15 Wire speed
16 MIG torch euro connection
17 Wire inch
18 Voltage adjustment
19 Shielding gas connection
20 Cable connection (14 pin control)
21 Wire feeder mechanical power connection (refer to 14)

17BOC Smootharc Advance II MIG 250R Operating manual
7.0 Troubleshooting and Fault Finding
Power source
Component Fault symptom Cause
Primary cable No or low welding output Bad or incorrect primary connection, lost phase
Earth cable and clamp Arc will not initiate Damaged, loose or undersized cables and clamps
Connectors and lugs Overheating of connectors andlugs Loose or badly crimped connectors
Switches Erratic or no output control Switches damaged or incorrectly set for the application
Fault indicator light (10) goes on No welding output Overheating. Allow machine to cool down for 10 mins. then
restart. If fault persists contact your service technician
Wire feeder
Component Fault symptom Cause
Gas solenoid valve No gas ow or gas ows continuously Gas valve faulty or sticking in open position
Wire feed rolls Wire slippage, wire deformation Incorrect feed roll size, incorrect tension adjustment,
misalignment
Inlet, outlet guides Wire shaving or snarling Incorrect wire guide sizes, misalignment
Universal adaptor Wire restriction, gas leaks, no trigger control Universal adaptor not correctly mounted or secured, incorrect
size of internal guide, bent contact pins
Wire feed speed control No control over wire feed speed, no amperage
control
Faulty wire speed feed potentiometer, wire feed motor in
overload or trip condition
Wire inch switch Wire live when feeding through cable and torch
before welding
Faulty wire inch switch, inappropriate use of torch trigger
switch
Spindle Wire spool drags or overruns Spindle brake set too tight or too loose, spool not properly
located on spindle
Welding torch
Component Fault symptom Cause
Type Welding torch overheats Welding torch underrated for welding application
Liners Erratic wire feed, wire snarls up at outlet guide Liner of incorrect type and size for wire in use, worn or dirty
liner, liner too long or too short
Gas distributor Inadequate gas ow, contaminated or porous weld Damaged or blocked distributor
Nozzle Inadequate gas cover, restricted joint accessibility Nozzle too large or too small, incorrect length or shape
Contact tip Erratic feeding, wire shudder, wire burnback,
unstable arc, spatter
Incorrect size of contact tip, incorrect contact tip to nozzle
distance for metal transfer mode, inferior contact tip material
Nozzle insulator Arcing between contact tip and nozzle and
between nozzle and workpiece
No nozzle insulator tted
Regulator / flowmeter
Component Fault symptom Cause
Inlet stem No gas ow, gas leaks at regulator body or
cylindervalve
Blocked inlet stem, leaking inlet stem to body thread, bullnose
not properly seated in cylinder case
Gas hose and tting Leaks at connections or in the hose, porosity in
theweld
Poorly tted ‘o’ clips, damaged hose, air drawn into gas stream
Shielding gas
Component Fault symptom Cause
Cylinder, MCPs No gas ow, porosity in the weld Gas cylinder closed or empty, faulty cylinder valves
Bulk No gas ow, change in welding conditions Bulk tank empty, incorrectly set mixing panel
Welding wire
Component Fault symptom Cause
Wire basket and spool Erratic wire feeding or wire stoppages Damaged wire basket, loose spooling, random-wound wire
Wire Wire sticks in contact tip, erratic feeding Varying wire diameter, copper aking, surface damage
Wire Weld has excessive amount of spatter Wrong polarity has been selected

18 BOC Smootharc Advance II MIG 250R Operating manual
8.0 Replacement Parts
Suitability Description Part No.
Torch
Binzel MB EVO PRO 24 3m 012.0371.1
Wire Feed Rollers
Self-Shielded Flux Cored Knurled 0.8–0.9 ADVANCEKNROL0809
Knurled 1.0–1.2 ADVANCEKNROL1012
Knurled 1.2–1.6 ADVANCEKNROL1216
Aluminium U Groove 0.8–0.9 ADVANCEUROL0809
U Groove 1.0–1.2 ADVANCEUROL1012
U Groove 1.2–1.6 ADVANCEUROL1216
Steel, Stainless Steel V Groove 0.6–0.8 ADVANCEVROL0608
V Groove 0.9–1.0 ADVANCEVROL0910
V Groove 1.0–1.2 ADVANCEVROL1012

19BOC Smootharc Advance II MIG 250R Operating manual
9.0 Periodic Maintenance
The working environment or amount of use the machine receives should
be taken into consideration when planning maintenance frequency of
your MIG 250R 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.
• Clean oxidised connections and tighten.
• Inner parts of machine should be cleaned
with a vacuum cleaner and soft brush.
• Do not use any pressure-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.

20 BOC Smootharc Advance II MIG 250R Operating manual
10.0 Warranty Information
10.1 Terms of Warranty
The Smootharc ADVANCE II 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.
10.2 Limitations on Warranty
The following conditions are not covered under terms of warranty: loss or
damage due to or resulting from natural wear and tear, non-compliance
with operating and maintenance instructions, connection to incorrect
or faulty voltage supply (including voltage surges outside equipment
specs), incorrect gas pressure overloading, transport or storage damage
or fire or damage due to natural causes (e.g. lightning or flood). This
warranty does not cover direct or indirect expenses, 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 and feeder guide tubes 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 to the product
without approval of the manufacturer, or if repairs are carried out using
non-approved spare parts. The warranty is void if a non-authorised
agent carries outrepairs.
10.3 Warranty Period
The warranty is valid for 3 years from date of purchase provided the
machine is used within the published specification limits.
10.4 Warranty Repairs
Your service provider must be informed within the warranty period
of any warranty defect. The customer must provide proof of purchase
and serial number of the equipment when making a warranty claim.
Warranty repairs may only be carried out by approved BOC service
providers. Please contact your local BOC Gas & Gear for a directory of BOC
approved service providers in your area.