Linde BOC Smootharc MMA130VRD User manual

MMA130/180VRD
Operating manual
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Welcome to a better way of welding
Congratulations on purchasing a Smootharc MMA 130/180 VRD welding
machine. Theproducts in BOC’s manual metal arc range perform with reliability
and have the backing of BOC’s national servicenetwork.
This operating manual provides the basic knowledge required for MMA and
DC TIG welding, as well as highlighting important areas of how to operate the
Smootharc MMA 130/180VRD welding machine.
With normal use and by following these recommended steps, your Smootharc
MMA 130/180 VRD welding machine can provide you with years of trouble free
service. BOCequipment and technical support is available through our national
BOC Customer Engagement 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.
MMA 130/180 VRD Operating manual2

Contents
1.0 Recommended safety guidelines 4
2.0 Recommended safety precautions 5
2.1 Health hazard information 5
2.2 Personal protection 5
2.3 Cylinder Safety 6
2.4 Electrical shock 7
2.5 User responsibility 7
Switch on to electrical safety 8
3.0 Technical specications 11
3.1 Package contents 11
4.0 MMA Installation 12
4.1 Install the Output Cables 12
4.2 Installing Adjustable Shoulder Strap 13
5.0 Control Panel 14
5.1 Control Panel 14
6.0 Operation 15
6.1 MMA Instructions 15
6.2 Diameter of Electrode 15
6.3 TIG Instructions 15
7.0 Environment 16
8.0 Troubleshooting 17
9.0 Periodic Maintenance 18
10.0 Warranty information 19
10.1 Terms of warranty 19
10.2 Limitations on warranty 19
10.3 Warranty repairs 19
11.0 Manual metal arc welding process (MMAW) 20
11.1 Process 20
11.2 Welding machine 20
11.3 Welding technique 21
11.4 Electrode selection 21
11.5 Types of joints 23
11.6 Fillet welds 25
12.0 Gas tungsten arc welding (GTAW/TIG) 29
12.1 Introduction 29
12.2 Process 29
12.3 Process variables 30
12.4 Welding techniques 31
12.5 Shielding gas selection 32
12.6 Welding wire selection 33
12.7 Tungsten electrode selection 34
12.8 Typical welding joints for gas tungsten
arcwelding 36
Appendix A Welding Parameter 37
3MMA 130/180 VRD Operating manual

→Repair or replace defective cables immediately.
→Never watch the arc except through lenses of the
correct shade.
→In conned spaces, adequate ventilation and
constant observation are essential.
→Leads and cables should be kept clear of
passageways.
→Keep re extinguishing equipment at a handy
location in the shop.
→Keep primary terminals and live parts
e󹟽ectivelycovered.
→Never strike an electrode on any gas cylinder.
→Never use oxygen for venting containers.
1.0 Recommended safety guidelines
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
Diagram and safety explanation
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
Some safety precautions BOC recommends are as follows:
This product is not intended for household or general use. This product is to be used
exclusively for commercial or industrial purposes by qualied welders in a workplace
where occupational health and safety legislation applies.
MMA 130/180 VRD Operating manual4

2.1 Health hazard information
The actual process of welding is one that can cause a
variety of hazards. All appropriate safety equipment
should be worn at all times, i.e. headwear, respiratory,
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.
2.2 Personal protection
Respiratory
Conned 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
conned 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 e󹟽ect 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 good enough
Eye protection
A welding helmet with the appropriate welding lter
lens for the operation must be worn at all times
in the work environment. The welding arc and the
reecting arc ash gives out ultraviolet and infrared
rays. Protective welding screen and goggles should be
provided for others working in the same area.
Clothing
Suitable clothing must be worn to prevent excessive
exposure to UV radiation and sparks. An adjustable
helmet, ameproof loose tting cotton clothing
buttoned to the neck, protective leather gloves,
spats, apron and steel capped safety boots are highly
recommended.
Recommended lter 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.
2.0 Recommended safety precautions
5MMA 130/180 VRD Operating manual

2.3 Cylinder Safety
Cylinder valve hand-wheel
Back-plug
Bursting disc
Back view of typical cylinder valve
Operatorwearing
personal protective
equipment (PPE)
insafe position
Ten points about cylinder safety
1Read labels and Material Safety Data Sheet
(MSDS) before use
2 Store 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
5 Always move cylinders securely with an
appropriate trolley. Take care not to turn the
valve on when moving a cylinder
6 Keep in a cool, well ventilated area, away
from heat sources, sources of ignition and
combustible materials, especially ammable
gases
7 Keep full and empty cylinders separate
8Keep ammonia-based leak detection
solutions, oil and grease away from cylinders
and valves
9 Never 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 ail 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
uid as this can damage the valve. Approved leak
detection uid, can be obtained from a BOC Gas &
Gear centre.
When nished with the cylinder, close the cylinder
valve by hand by turning the valve hand-wheel in a
clockwise direction. Use only reasonable force.
MMA 130/180 VRD Operating manual6

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.
2.4 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
→Never changing electrodes with bare handsorwet
gloves
→Never cooling electrode holders in water
→Working on a dry insulated oor where possible
→Never hold the electrode and holder
underyourarm
2.5 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 qualied 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 Pacic.
STOP
PLEASE NOTE that under no circumstances
should any equipment or parts be altered
or changed in any way from the standard
specication 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]
7MMA 130/180 VRD Operating manual

8
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BOC welding machines are designed and manufactured
to conform to IEC 60974 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
A S 60974-1
Formula in clause 3.33
Maximum effective supply current
I1eff = √I12×X+ I02(1-X)
The I1e󹠢 determines thecorrect plug, input cable
andinput current required for each machine.
10A
I1eff ≤
I1eff ≤
I1eff ≤
I1eff ≤
1. 5 – 2 .5 m m 2
m i n – m a x cable size
size must be indicated
on the cable
15A 1. 5 – 4 m m 2
25A 2 . 5 – 6 m m 2
32A 4–10mm2
Before operating your welding machine, follow the instructions in the
operating manual. 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…
Switch on to
electrical safety
for single-phase equipment

9
DO
Example
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re.
For your safety, BOC meets AS/NZS Standards
for safe electricalcompliance.
Regulatory Compliance Mark
(RCM) andnumber
All BOC welding machines undergo an
independent certication process to meet
Australian and New Zealand regulations
regarding electrical safety. The triangle-
circle-tick (RCM) symbol signies that BOC
has taken the necessary steps to have the
product comply with the electrical safety
and/or electromagnetic compatibility (EMC)
legislative requirements as specied 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.
✓ 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.
If the I1e󹠢 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.

10
DON‘T
Example of BOC rating plate
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. E󹟽ective rated primary current (I1e󹟽 )
combines the conductor heating due to these two
levels of current. I1e󹟽 is the maximum rated e󹟽ective
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 I1e󹟽 on the welding machine’s rating plate
and ensure that you have the correct input circuit to
support this powerdraw.
✖ Don’t risk damage to your machine or
cause tripping and/or re by using the
wrong input current, cable orplug.
✖ Don’t tamper with plugs or ledown
earth pins. Doing so willvoidwarranty.
Always
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 qualied 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 re in the
building which may voidinsurances.
✓ Inspect cables and plugs regularly.
✓ Contact a qualied electrician for
advice and/or upgrade and, if
needed, to replace any damaged plugs
orcables.
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Specications MMA 130 VRD MMA 180 VRD
Part No. BOCMMA130VRD BOCMMA180VRD
Power voltage Single phase AC240 V ±15% Single phase AC240 V ±15%
Frequency 50/60 Hz 50/60 Hz
MMA TIG MMA TIG
Maximum rated input current (I1max) 22.1 A 20.3 A 38 A 30 A
Maximum e󹟽ective supply current
(I1e󹠢)
9.8 A 9.1 A 14.7 A 13.4 A
Output current range 10–130 A 10 – 170 A 10–180 A 10–200 A
Output voltage range 20.4 – 25.2 V 10.4 – 16.8 V 20.4 – 27.2 V 10.4– 18 V
Duty cycle @ 15% – – 180 A –
20% 130A 170 A – 200 A
60% 98 A 98 A 90 A 116 A
100% 59 A 76 A 70 A 89 A
No-load voltage 79 V 79 V
No-load loss (Idle state power
consumption)
40 W 40 W
Power factor 0.73 0.73
E󹟾ciency (%) 80% 80%
Min. recommended generator rating 7 kVA 11 kVA
Insulation grade F F
Housing protection grade IP23 IP23
Weight 5.5 kg 5.5 kg
Dimension (L × W × H) 365 × 172 × 320 mm 365 × 172 × 320 mm
Standards AS/NZS 60974-1, IEC/EN 60974-10, AS 1674-2 Category C Environment
3.1 Package contents
Smootharc MMA 130 VRD
Power source with input cable and plug – 10A
Electrode holder – 3m
Work return lead – 3m
Operating manual
Smootharc MMA 180 VRD
Power source with input cable and plug – 15A
Electrode holder – 3m
Work return lead – 3m
Operating manual
3.0 Technical specications
11MMA 130/180 VRD Operating manual

Output Terminals
Negative output terminal
Positive output terminal
4.1 Install the Output Cables
There are two welding methods for MMA welding,
please choose according to the actual
electrode manufacturer recommendations.
Direct Current Electrode Negative (DCEN)
The positive output terminal is connected to the
workpiece, and the negative output terminal is
connected to the electrode holder.
Direct Current Electrode Positive (DCEP)
The positive output terminal is connected to the
electrode holder, and the negative output terminal is
connected to the workpiece.
4.0 MMA Installation
MMA 130/180 VRD Operating manual12

4.2 Installing Adjustable Shoulder Strap
The images shown here are indicative only. Ifthere is
any inconsistency between the image and the actual
product, the actual product shall govern.
Fix the belt as gure 1 to 3. The length of the beltcan
be adjusted as needed.
Figure 1
Figure 2
Figure 3
13MMA 130/180 VRD Operating manual

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Icon Name Description
Adjusting Knob Used to adjust welding current.
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Power Indicator -
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Abnormal Indicator This indicator lights up when the machine is overheated, overcurrent,
or other abnormal condition.
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VRD Indicator When the VRD function is active the VRD indicator lights up.
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TIG/MMA Switch Switch TIG / MMA welding mode
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Power Switch Turn on/o󹟽 the power.
5.1 Control Panel
5.0 Control Panel
MMA 130/180 VRD Operating manual14

6.1 MMA Instructions
Steps Description
1 Select electrode It is suggested to choose the diameter of electrode according to the thickness
of the workpiece refer to the following table (Diameter of Electrode).
2 Starting up Turn on the power switch.
3 Select MMA mode Select MMA mode through TIG/MMA switch
4 Set up parameters Set welding current according to electrode, workpiece and welding process.
After the setup is complete, you can begin the welding operation.
6.2 Diameter of Electrode
Thickness of workpiece (mm) Diameter of electrode (mm)
＜4 The diameter of the electrode should not exceed the thickness of the
workpiece.
4~12 3.2~4.0
6.3 TIG Instructions
Steps Description
1 Starting up Turn on the power switch.
2 Select TIG mode Select TIG mode through TIG/MMA switch
3 Set up parameters Set welding current according to electrode, workpiece and welding process.
After the setup is complete, you can begin the welding operation.
TIG torch part number MMA-TIG is available as an optional extra. Please note to connect the TIG torch as DC electrode negative polarity (DCEN). This means the TIG torch
should be connected to the negative terminal and the work return lead to the positive terminal.
6.0 Operation
15MMA 130/180 VRD Operating manual

Note: The power source should not be used in rain or
snow environment.
The recommended external environment for welding
is as follows:
→Please place the power source in a horizontal
position. The inclination of the power source
should notexceed10 degrees.
→The environment where the equipment is stored
should be clean and protected from dust.
→Dust, acids, corrosive gases or substances in the
surrounding air should not exceed normal levels,
except those produced by the welding process.
The environment where the equipment is
stored needs to be dry. The relative humidity
recommendations are as follows:
→No more than 50% at 40°C.
→No more than 90% at 20°C
The equipment should be shielded from heat, re
and welding spatter. Theambient temperature
requirements are asfollows:
→During welding: -10°C to +40°C
→During transportation and storage: -20°C to +55°C
7.0 Environment
MMA 130/180 VRD Operating manual16

8.0 Troubleshooting
Polarity, tment of cables, condition of connections,
condition of materials being welded, environment,
input power supply may all inuence the welding
process.
No. Problems Solution
1Arc starting is di󹟾cult
and the arc is
di󹟾cult to maintain.
Check the condition of the electrodes. If the electrode is not dry, it will cause
unstable arc, cracking, and porosity in the weld.
2Excessive spatter Current selected too high for the electrode diameter.
Incorrect polarity.
Damp electrodes.
17MMA 130/180 VRD Operating manual

It is recommended that the unit be serviced in
accordance with the requirements of IEC 60974-4.
→Check electrical connections before every use.
Repair or replace broken/damaged cables.
→Clean oxidised connections and tighten.
→Inner parts of machine should be cleaned with
avacuum cleaner and soft brush.
→Avoid water or moisture ingress into machine.
9.0 Periodic Maintenance
MMA 130/180 VRD Operating manual18

10.1 Terms of warranty
BOC provides a full replacement warranty for the
Smootharc MMA 130/180 VRD sold by it against
defects in manufacture andmaterials.
→Valid for 3 years from date of purchase.
→Freight, packaging and insurance costs are to be
paid for by the claimant.
→No additional express warranty is given unless in
writing signed by an authorised manager of BOC.
→This warranty is in addition to any other legal
rights you may have.
→Electrode holders, work return clamps, and all
leads are not covered.
10.2 Limitations on warranty
The following conditions are not covered:
→Non compliance with operating and maintenance
instructions such as connection to incorrect faulty
voltage supply including voltage surges outside
equipment specications, and 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 parts.
→A non-authorised agent carries out repairs.
10.3 Warranty repairs
BOC or their Authorised Service Agent must be
informed of the warranty defects, and the product
returned within the warranty period.
→Before any warranty replacement, the customer
must provide proof of purchase and serial number
of the equipment in order to validate the warranty.
→The machines replaced under the terms of the
warranty remain the property of BOC.
10.0 Warranty information
19MMA 130/180 VRD Operating manual

11.1 Process
Manual Metal Arc welding is the process of joining
metals where an electric arc is struck between the
metal to be welded (parent metal) and a ux-coated
ller wire (the electrode). Theheat of the arc melts
the parent metal and the electrode which mix
together to form, on cooling, a continuous solid mass.
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Before arc welding can be carried out, a suitable
power source is required. Two types of power sources
may be used for arc welding, direct current (DC) or
alternating current (AC).
The essential di󹟽erence between these two power
sources is that, in the case of DC, the current remains
constant in magnitude and ows in the same
direction. Similarly, the voltage in the circuit remains
constant in magnitude and polarity (i.e. positive or
negative).
In the case of AC however, the current ows rst in
one direction and then the other. Similarly, the voltage
in the circuit changes from positive to negative with
changes in direction of current ow. This complete
reversal is called a ‘half cycle’ and repeats as long as
the current ows. The rate of change of direction of
current ow 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).
11.2 Welding machine
The most important consideration when contemplating
the use of arc welding for the rst 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 operate from standard 240 Volt
powerpoint to heavy-duty welders used by the largest
steel fabricators.
Basic welding machine and cables
The choice of welding machine is based mostly on the
following factors:
→primary voltage, e.g. 240 Volt or 380 Volt
→output amperage required, e.g. 140 amps
→output required, e.g. AC or DC +/-
→duty cycle required, e.g. 35% @ 140 amps
→ method of cooling, e.g. air-cooled or oil-cooled
method of output amperage control, e.g. tapped
secondary lugs
→or innitely variable control.
For example, the Smootharc 171 connects to 240 Volt
supply (15 amps Input), has an output of 170 amps DC
@ 50% duty cycle.
11.0 Manual metal arc welding process (MMAW)
MMA 130/180 VRD Operating manual20