Linde BOC Smootharc Advance MIG 425R User manual

MIG 425R & 555R
Operating Manual

2BOC Smootharc Advance III MIG 425R & 555R 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 trouble-free service.
Smootharc ADVANCE equipment and technical support is available through
the national BOC Customer Service Centre or contact your local BOC store.
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 III MIG 425R & 555R Operating manual
Contents.
1.0 Recommended Safety Guidelines andPrecautions 4
1.1 Health Hazard Information 5
1.2 Personal Protection 5
1.3 Cylinder Safety 6
1.4 Electrical shock 7
1.5 User Responsibility 7
Switch on to electrical safety 8
2.0 Package Contents 10
3.0 Technical Specications 11
4.0 Quick Overview 12
5.0 Installation 13
5.1 Installation for Standard MIG/MAG process 13
5.2 Installation for TIG process 14
5.3 Installation for MMA process 14
6.0 Control panel 15
6.1 Main functions 15
6.2 Home Screen Icons 16
6.3 Welding parameter Icons 16
6.4 Main Settings (Welding parameters) 17
6.5 Second Settings screen (Level 2 parameters) 18
6.6 JOB Screen 19
6.7 Retrieving JOBs 19
6.8 2T/4T Trigger Latch Setting explained 19
6.9 Service Screen 20
6.10 Error Screen 20
6.11 Gas Test Screen 21
6.12 Inch Screen 21
6.13 Aluminium Welding & Additional Notes 21
7.0 Operating your machine 22
7.1 Operation Instructions for MIG 22
7.1.1 Inductance 23
7.1.2 4T/2T Trigger Latch Selection 23
7.2 Operation instruction of 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 26
9.2 Limitations on Warranty 26
9.3 Warranty Period 26
9.4 Warranty Repairs 26
10.0 MIG Process 27
10.1 Introduction to Metal Inert Gas (MIG) 27
10.2 Introduction to Flux Cored Arc Welding (FCAW) 27
10.3 Introduction to Metal Cored Arc Welding (MCAW) 29
10.4 Fundamentals of MIG, FCAW and MCAW 31
11.0 Gas tungsten arc welding (GTAW/TIG) 34
11.1 Introduction 34
11.2 Process 34
11.3 Process variables 35
11.4 Shielding gas selection 36
11.5 Welding wire selection 36
11.6 Tungsten electrode selection 37
11.7 Welding techniques 39
11.8 Torch movement during welding 39
11.9 Positioning torch tungsten for various weld joints 40
11.10 Joint preparation 41
12.0 MMA Process 43
12.1 Process 43
12.2 Welding Machine 43
12.3 Welding Technique 44
12.4 Electrode Selection 44
12.5 Types of Joints 46
12.6 Fillet Welds 48
12.7 TypicalDefectsDuetoFaultyTechnique 50
13.0 Indicative Welding Parameters 52
13.1 Mild Steel Solid Wire 52
13.2 Mild Steel Flux Cored Wire 52
13.3 Stainless Steel Solid Wire 53
13.4 Aluminium Solid Wire 53
14.0 Correct Application Techniques 54

4BOC Smootharc Advance III MIG 425R & 555R 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 III MIG 425R & 555R 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.