Smootharc TIG 185 AC/DC Operating manual
Contents
1. 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 T 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 N and 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 amp 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 reasona2. to weld brass will lose ing is attempted and welding is not recommeded for those Copper and copper alloy welding parameters Plate thickness mm Joint type Root gap mm Layers Tungsten size mm Consumable size mm Current A Welding speed cm min Gasflow l min 15 Square butt 1 0 1 1 6 2 0 120 0 29 7 3 Square butt 2 0 1 3 2 3 0 185 0 25 8 5 Square butt 3 0 2 4 0 4 0 270 0 15 8 BOC Smootharc TIG 185 AC DC Operating Manual 21 4 0 Package Contents Front Connections of TIG 185 AC DC ro Vj ie oy roy AC BALANCE 2 5 DOWN SLOPE post Row Negative output terminal Gas electricity system output terminal Torch switch socket Positive output terminal Package Contents Power source Work return lead TIG torch MMA electrode holder and cable Regulator Gas hose Spare parts sticker Operator s manual BOC Smootharc TIG 185 AC DC Operating Manual 5 0 Smootharc TIG 185 AC DC Installation Installation configuration of TIG 185 AC DC WARNING Before installing please ensure that all the power is turned off Connect the welding cable and ground cable to the machine first then make sure they are firmly connected before putting the power plug to the power source 1 To prevent significant voltage drop by using excessively long cables it is recommended to increase the cable diameter
3. Open joint groove he most common cause is moisture or aspirated air in gas stream Use welding grade gas only Find the source of the contamination and eliminate it promptly Use appropriate chemical cleaners wire brush or abrasives prior to welding Inclusion of tungsten or oxides in weld Cause Excessive current for tungsten size used Accidental contact of electrode with puddle Accidental contact of electrode to filler rod Using excessive electrode extension nadequate shielding or excessive drafts Wrong gas Heavy surface oxides not being removed Solution Reduce the current or use larger electrode aintain proper arc length aintain a distance between electrode and filler metal Reduce the electrode extension to recommended limits ncrease gas flow shield arc from wind or change to gas saver or gas lens Do not use ArO or ArCO GMAW MIG gases for TIG welding Use ACHF Adjust balance control for maximum cleaning or wire brush and clean the weld joint prior to welding Porosity in Weld Deposit Cause Defective gas hose or loose connection Filler material is damp particularly aluminiu Filler material is oily or dusty phosphorous lead and zinc Excessive travel speed with rapid freezing o gases before they escape Contaminated shield gas Entrapped impurities hydrogen air nitrogen water vapour m Alloy impurities in the base metal such as sulphur weld trapping
4. other con aminants must be removed before welding Copper alloys containing aluminium will form a surface oxide film and this must also be f emoved before welding Preheat will be required for unalloyed copper but some copper alloys can be TIG welded without preheat except on t Standard C curren Pure a gases is idea thicker C I c and cupro c a hic sections DC TIG welding equipment is suitable for most copper and opper alloys but aluminium bronze is normally TIG welded using AC opper allo ompositio nd someti Porosity is u G consumables are solid fi to break down the tenacio gon helium or argon heliu or DC TIG welding copper a for TIG welding copper and sections Pure argon is the y compositions nickels It is normal to t mes not desirable containing lead shie ller rods ba including al y to n to that of the parent mate uminium use a fil ial but t he main welding problem encounte nalloyed copper and some copper alloys are prone to solidification acking and porosity Certain alloys are difficul zinc if weld us oxide film on the surface m mixtures are standard shielding nd copper alloys Alushield Heavy some copper alloys particularly in ding gas used for AC TIG welding sed on pure copper and several bronzes silicon bronzes er material with a similar his is not always possible ed when TIG welding
5. 2 Ensure free flow of air around machine to avoid overheating 3 Connect the gas cylinder to the regulator Select the correct shielding gas for the application 4 Insert the earth return lead connection into the front face panel Ensure that the equipment is correctly connected depending on the process selected For TIG welding the work return lead should be connected to the positive output connection and the TIG torch to the negative output connection BOC Smootharc TIG 185 AC DC Operating Manual 23 6 0 Control panel Control Panel of TIG 185 AC DC Frequency switch MMA TIG switch AC DC switch 2T 4T switch Current meter Over heat protection indicator Over current protection indicator 2 5 1 POST FLOQW Down AC balance adjustment OWN SLOPE Welding current adjustment Down slope adjustment Post flow adjustment 6 1 Function switches 1 AC DC switch AC switch intended for aluminium DC position is for all other materials 2 21 47 switch 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 Remember a defective weld may not be detected by a visua
6. Solution Do not weld on wet material Check hoses and connections for leaks Dry filler metal in oven prior to welding Replace filler metal Change to a different alloy composition which is weldable These impurities can cause a endency to crack when hot Lower the travel speed Replace the shielding gas 26 BOC Smootharc TIG 185 AC DC Operating Manual Cracking in Welds Cause Hot cracking in heavy sections or welding on metals prone to hot cracking Post weld cold cracking due to excessive joint restraint rapid cooling or hydrogen embrittlement Centreline cracks in single pass weld Underbead cracking from brittle microstructure Solution Increase weld bead cross section size Change weld bead contour for e g concave to flat or convex check fit up gap reduce welding speed Preheat prior to welding Use pure or non contaminated gas Increase the bead size Prevent craters or notches Change the weld joint design Increase bead size Decrease root opening Use preheat Prevent craters Eliminate sources of hydrogen joint restraint and use preheat Inadequate shielding Cause Gas flow blockage or leak in hoses or torch Excessive travel speed exposes molten weld to atmospheric contamination Wind or drafts Excessive electrode stickout Excessive turbulence in gas stream Solution Locate and eliminate the blockage or leak Use slower travel speed or carefully increase the flow rate to a safe lev
7. 6000 series BOC Mild steel TIG wire Comweld CrMo1 Comweld CrMo2 Profill 308 Profill 316 Profill 309 Profill 347 Comweld 1100 Comweld 4043 4047 5356 Comweld 4043 4047 5356 Filler rod diameter mm Thickness of metal mm 2 3 4 4o0r5 5 oF 6 0 5 2 2 5 5 8 8 12 12 of more BOC Smootharc TIG 185 AC DC Operating Manual 11 2 6 Non consumable Tungstens Tungsten Electrode Selector Chart Welding Thickness range Desired results current Electrode type Shielding gas Tungsten performance characteristics Aluminium alloys and Magnesium alloys All General purpose ACHF Only thin sections Control DCRP penetration Only thick sections Increase DCSP penetration or travel speed Copper alloys Cu NI alloys and Nickel alloys All General purpose DCSP Only thin sections Control ACHF penetration Only thick sections Increase DCSP penetration or travel speed Pure EW P Zirconiated EW Zr 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Thoriated EW Th2 2 Ceriated EW Ce2 Zirconiated EW Zr 2 Ceriated EW Ce2 Argon Argon 75 Argon 25 Helium Argon Helium 75 Argon 25 Helium Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium Mild Steels Carbon Steels Alloy Steels Stainless Steels and Titanium alloys All General purpose D
8. alloys Alternating current 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 and fast cooling will produce a hard HAZ and this is liable to result in hydrogen cracking This form of cracking can be prevented by use of preheat and suitable welding procedures C Mn steel welding parameters Plate thickness mm 0 8 1 15 2 1 1 5 2 Joint type Fillet Fillet Fillet Fillet Butt Butt Butt Number of passes 1 1 1 1 1 1 1 Tungsten electrode mm 1 6 1 6 1 6 2 4 1 6 1 6 2 4 Consumable size mm 1 5 15 2 2 5 15 2 2 5 Current A 70 90 110 130 80 120 140 Welding speed cm min 30 30 30 25 20 20 20 Gasflow l min 5 5 6 6 6 7 7 Shielding gas Argon Consumable ER70S 6 Position Downhand Polarity DC 18 BOC Smootharc TIG 185 AC DC Operating Manual 3 3 Alloyed steel TIG welding may be used for welding alloy steels but because deposition rates are low it is usually only used for welding sheet and thin sections for high quality applications small components and root passes of multipass butt joints in plate and pipe Standard DC TIG equipment is normally suitable and DCEN polarity is usually chosen to provide good workpiece heating Tungsten electrodes with additions of thorium oxide cerium oxide or lanthanum oxide are used for welding steel and they give good arc stability Only inert or reducing
9. gases should be used for TIG welding and pure argon is normally recommended as the shielding gas for welding alloy 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 Alloy steels with high carbon equivalents are hardenable and fast cooling will produce a hard HAZ and this is liable to result in hydrogen cracking This form of cracking can be prevented by use of preheat and suitable welding procedures General welding parameters 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 good surface finish are critical The process has a high degree of controllability resulting in clean smooth high quality welds with good penetration and strength with very low defect rates Standard TIG equipment is suitable and stainless steels are TIG welded using DCEN polarity A thoriated tungsten electrode is normally used but health concerns have promoted use of ceriated or lanthanated instead The filler rod used depends on the type of stainless being welded but in general is matching for austenitic grades enriched in nickel for duplex grades and may be matching or an austenitic type for ferritic and martensitic grades Shielding gas is conventionally pure argon but other g
10. 1 3 11 4 Recommended Safety Guidelines and Precautions Health Hazard Information Personal Protection Electrical shock User responsibility Gas tungsten arc welding GTAW TIG Introduction Process Process variables Shielding gas selection Welding wire selection Non consumable Tungstens Welding techniques Torch movement during welding Positioning torch tungsten for various weld joints Joint preparation TIG Welding of Materials Application summary CMn steel Alloyed steel Stainless steel Aluminium Balanced Squarewave Copper and copper alloys Package Contents Smootharc TIG 185 AC DC Installation Control panel Function switches Adjustment knobs Indicator function Smootharc TIG 185 AC DC Operation Operation for AC welding Operation for DC welding Operation for MMA welding Troubleshooting and Fault Finding Periodic Maintenance Power Source Technical Specifications Warranty Information Terms of Warranty Limitations on Warranty Warranty Period Warranty Repairs NN UU co co 00 10 11 12 12 14 15 17 17 17 18 18 19 19 20 21 22 23 23 23 23 24 24 24 24 25 27 27 28 29 29 29 29 29 BOC Smootharc TIG 185 AC DC Operating Manual 1 0 Recommended Safety Guidelines and Precautions Diagram and safety explanation Electrical safety alert Welding electrode causing electric shock Fumes and gases coming from welding process Weldi A e
11. 28 BOC Smootharc TIG 185 AC DC Operating Manual 10 0 Technical Specifications Specifications MMA TIG Part No TIG185ACDC Power voltage AC Single phase 240V 15 Frequency 50 60 Hz Rated input current 30 4A 28A Output current 10 to 150A 10 to 185A Rated working voltage 26V 18V o load voltage 59V Duty cycle 60 Arc initiation HF Remote control NO Efficiency 80 Power factor 0 73 nsulation grade F Housing protection grade IP21 Dimensions Lx W x H 450x204x368 mm Weight 14 7 kg Standards IEC 60974 1 10 BOC Smootharc TIG 185 AC DC Operating Manual 29 11 0 Warranty Information 11 1 Terms of Warranty The Smootharc 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 11 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 los
12. CSP Only thin sections Control ACHF penetration Only thick sections Increase DCSP penetration or travel speed 2 Thoriated EW Th2 2 Ceriated EW Ce2 2 Lanthanated EWG La2 Zirconiated EW Zr 2 Ceriated EW Ce2 2 Lanthanated EWG La2 75 Argon 25 Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium Helium Balls easily Low cost Tends to spit at higher currents Used for non critical welds only Balls well Takes higher current with less spitting and with better arc starts and arc stability than pure tungsten Higher current range and stability Better arc starts with lower tendency o spit edium erosion Lowest erosion rate Widest current range AC or DC No spitting Best arc starts and stability Best stability at medium currents Good arc starts Medium tendency to Spit edium erosion rate Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Best stability at medium currents Good arc starts Medium tendency to spit edium erosion rate Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Use on lower currents only Spitting on starts Rapid erosion rates at higher currents Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Best stability at medium curren
13. Indicator function 1 Over heat protection indicator This indicator light will illuminate when the duty cycle of the machine has been exceeded The machine will normally reset itself after 2 3 minutes 2 Over current protection indicator This indicator will illuminate when an accidental over current has occurred 24 BOC Smootharc TIG 185 AC DC Operating Manual 7 0 Smootharc TIG 185 AC DC Operation WARNING Do not connect or disconnect the machine cables whilst welding as this may cause serious harm to yourself and or the machine 71 Aa WN Operation for AC welding Set the AC DC switch to AC Turn on power switch fan will operate continuously Turn on shielding gas and regulate gas flow to specified flow rate Select the AC balance control based on the degree of cleaning of the base material that is required Press the contactor switch on the welding torch to start up the electromagnetic valve The sound of the high frequency spark discharge in the welding machine will be audible and the shielding gas will flow The post flow can be regulated by adjusting the post flow adjustment 7 2 Operation for DC welding a W N 5 Set the AC DC switch to DC Turn on power switch fan will operate continuously Turn on shielding gas and regulate gas flow to specified flow rate Press the contactor switch on the welding torch to start up the electromagnetic valve The sound of the high frequency spark discharge
14. N in following ways High heat is produced on the electrode rather on the base metal The heat melts the tungsten electrode tip The base metal remains relatively cool compared to using straight polarity Relatively shallow penetration is obtained An electrode whose diameter is too large will reduce visibility and increase arc instability Welding with alternating current combines both direct current characteristics In the positive phase cleaning action occurs in the weld puddle During the negative phase heat is concentrated in the weld puddle The above causes increased penetration For a given diameter of tungsten electrode higher amperage can be used with straight polarity Straight polarity is used mainly for welding Carbon steels Stainless steels Copper alloys The increased amperage provides Deeper penetration Increased welding speed A narrower deeper weld bead 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 10 BOC Smootharc TIG 185 AC DC Operating Manual 2 4 Shielding gas selection Material Aluminium Alloys Aluminium Bronze Brass Cobalt based alloys Copper nickel Monel Deoxised copper Nickel alloys Inconel Steel Magnesium Alloys Stainless steel Titanium Shielding gas Argon Argon Helium Argon A
15. Smootharc Smootharc TIG 185 AC DC Operating manual Smoothart AOD M7 BOC A Member of The Linde Group 2 BOC Smootharc TIG 185 AC DC Operating Manual Welcome to a better way of welding This operating manual provides the basic knowledge required for TIG welding as well as highlighting important areas of how to operate the Smootharc TIG 185 AC DC machine With normal use and by following these recommended steps your Smootharc TIG 185 AC DC machine can provide you with years of trouble free service BOC equipment and technical support is available through our national BOC Customer Service Centre or contact your local Gas amp Gear outlet 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 specific 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 verified the accuracy of the information cont
16. a flat spot Diameter of flat spot determines amperage capacity See below The included angle determines weld bead shape and size Generally as the included angle increases penetration increases and bead width decreases Use a medium 60 grit or finer aluminium oxide wheel Tungsten extension Tungsten electrode tip shapes and current ranges Constant Electrode Diameterarc included angle Current range diameter mm _ tip mm degrees A 1 0 0 125 12 2 15 120 0 250 20 5 30 1 6 0 500 25 8 50 1 6 0 800 30 10 70 2 3 0 800 35 12 90 2 3 1 100 45 15 150 3 2 1 100 60 20 200 3 2 1 500 90 25 250 Standard Parts gt 4 General purpose 3x Dia Gas Lens Parts gt General purpose L___ 3x Dia Maximum 6x Dia gt in draft free areas 14 BOC Smootharc TIG 185 AC DC Operating Manual 2 9 Positioning torch tungsten for various weld joints Butt Weld and Stringer bead Corner Joint IS 79 90 N i 75 f tO S aie nn 4 AS 15 T Joint Lap Joint 20 40 ba 20 ale e is Ne gt a Pa A 152 7 e t BOC Smootharc TIG 185 AC DC Operating Manual 15 2 10 Joint preparation All measuremen ts in mm 16 BOC Smootharc TIG 185 AC DC Operating Manual Condition Result Porosity Long arc length Undercut l l Wide bead p
17. ained 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 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 affiliates 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 suffered 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 BOC Smootharc TIG 185 AC DC Operating Manual Contents 1 0 1 1 1 2 1 3 1 4 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 4 0 5 0 6 0 6 1 6 2 6 3 7 0 71 7 2 7 3 8 0 9 0 9 1 10 0 11 0 11 1 11 2 1
18. ases are available o provide specific properties and these include argon hydrogen argon helium mixtures argon helium hydrogen and argon nitrogen mixtures When welding pipes an inert gas purge is required inside the pipe to prevent oxidation on the underside of the weld Gas purging may also be used to protect the root side of butt welds in plate or sheet materials too Plate thickness mm 1 1 5 2 Tungsten electrode mm 1 1 6 1 6 Gas flow l min 3 4 3 4 4 Current A 30 60 70 100 90 110 Consumable size mm 1 1 5 1 5 2 0 3 5 6 8 12 1 6 2 4 2 4 3 2 3 2 4 0 4 4 8 6 4 4 5 4 6 5 6 5 6 5 7 120 150 190 250 220 340 300 360 350 450 2 0 3 0 3 0 4 0 4 0 6 0 4 0 6 0 4 0 6 0 Polarity DC BOC Smootharc TIG 185 AC DC Operating Manual 19 3 5 particu TIG we standa operated with or witho electrode Aluminium arly in section si ding of aluminiu d operating mod negati AC is th elec efficien film occurs rode negative cycle Wi be removed to allow fu e most frequent on the elect ve DCEN and di m can be carried y used since wi ode fusion to take tly Gis a high quality process widely used for welding aluminium ze up to about 6mm The process may be ut filler out using any of the three es alternating current AC direct current ect current electrode positive DCEP SUE place and AC TIG does allowing high q
19. ble 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 BOC Smootharc TIG 185 AC DC Operating Manual 7 ko Neve Alway Electrical shock touch live electrical parts s repair or replace worn or damaged parts Disconnect power source before performing any maintenance or service gt Earth Neve Avoid electric Weari Weari Neve Neve Worki Neve 1 4 gt Read Unauthorised repairs or modifica all work materials work in moist or damp areas shock by ng dry insulated boots ng dry leather gloves changing electrodes with bare hands or wet gloves cooling electrode holders in water ng on a dry insulated floor where possible hold the electrode and holder under your arm User responsibility the Operating Manual prior to installation of this machine ions to this equipment may endanger the technician and operator and will void your warranty Only qualified perso nnel approved by BOC should perform repairs Always disconnect mains power before investigating equipment malfu Parts imme nctions that are broken damaged missing or worn should be replaced diately Equipment should be cleaned periodically BOC with stock a huge range of personal protective equipment This combined BOC s extensive Ga
20. el below creating excessive turbulence Use a trailing shield cup Set up screens around the weld area Reduce electrode stickout Use a larger size cup or switch to gas saver or gas lens Change to gas safer parts or gas lens parts Short parts Life Cause Cup shattering or cracking in use Short collet life Short torch head life Solution Change cup size or type Change tungsten position Ordinary style is split and twists or jams Change to wedge style Do not operate beyond rated capacity Do not bend torche heads BOC Smootharc TIG 185 AC DC Operating Manual 27 9 0 Periodic Maintenance WARNING Only authorised electricians should carry out repairs and internal servicing Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void The working environment or amount of use the machine receives should be 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 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
21. he 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 insufficient 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 alumini
22. he tungsten may be connected to either output terminal but is most often connected to the negative pole The output characteristics of the power source can have an effect on the quality of the welds produced Shielding gas is directed into the arc area by the welding torch and a gas lens within the torch distributes the shielding gas evenly over the weld area In the torch the welding current is transferred to the tungsten electrode from the copper conductor The arc is then initiated by one of several methods between the tungsten and the workpiece BOC Smootharc TIG 185 AC DC Operating Manual 2 3 Process variables Process variable Explanation Usage DCEN Narrow bead deep penetration Nozzle Electrons ins oO DCEP Wide bead shallow penetration Nozzle Electrons ons eS S Alternating Current with High Frequency Average bead Average penetration Nozzle lons E N ie A wy When direct current electrode negative straight polarity is used Electrons strike the part being welded at a high speed Intense heat on the base metal is produced The base metal melts very quickly lons from the inert gas are directed towards the negative electrode at a relatively slow rate Direct current with straight polarity does not require post weld cleaning to remove metal oxides The DCEP reverse polarity are different from the DCE
23. in the welding machine will be audible and the shielding gas will flow The post flow can be regulated by adjusting the post flow adjustment 7 3 Operation for MMA welding Switch MMA TIG switch to MMA Turn on power switch fan will operate continuously Select proper welding current according to the electrode manufacturer s specification BOC Smootharc TIG 185 AC DC Operating Manual 25 8 0 Troubleshooting and Fault Finding Excessive electrode consumption Cause nadequate gas flow nadequate post gas flow mproper size electrode for current required perating of reverse polarity ectrode contamination xcessive heating inside torch ectrode oxidising during cooling O nmm m Solution ncrease gas flow ncrease post flow time to 1sec per 10amps Use larger electrode User larger electrode or change polarity Remove contaminated portion then prepare again Replace collet Try wedge collet or reverse collet ncrease gas flow post time to 1 sec per 10amps hielding gas incorrect Change to Argon no oxygen or CO Erratic Arc Cause Solution ncorrect voltage arc too long Current too low for electrode size Electrode contaminated oint too narrow weld bead indicate contamination Base metal is oxidised dirty or oily Contaminated shield gas Dark stains on the electrode or aintain short arc length Use smaller electrode or increase current Remove contaminated portion then prepare again
24. l inspection 3 MMA TIG switch Allows you to switch between TIG and MMA welding 4 Frequency switch Changes the pulse frequency 6 2 Adjustment knobs 1 Welding current adjustment Adjusts welding current 2 AC balance adjustment In addition to increasing the welding current in AC applications a change in the penetration or cleaning when welding can be achieved by adjusting the AC Balance 3 The AC balance time spend in the positive maximum cleaning or negative maximum penetration can be adjusted by using the AC balance adjustment By adjusting the AC balance adjustment from 20 100 progressively increases the time in the positive side of the AC curve higher heat concentration in the non consumable tungsten electrode This has the result that the amount of penetration is decreased 4 With the AC balance adjustment set at 20 higher currents can be used on thinner electrodes resulting in the use of smaller gas cups therefore increasing visibility and reducing gas flows 5 Down slope adjustment Down slope adjustment allows a gradual decrease control 6 Post flow in amperage at the end of the weld to improve crater adjustment Allows a variable flow of shielding gas after current has been switched off to ensure that no oxidation of both the tungsten and the weld pool happens 7 Welding current adjustment When switched to MMA function only the current control knob is active 6 3
25. lding 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 filter 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 BOC Smootharc TIG 185 AC DC Operating Manual 1 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 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 t
26. m au 970 988 Great South Road Penrose Auckland New Zealand www boc co nz BOC Limited 2012 BOC is a trading name of BOC Limited a Member of The Linde Group Reproduction without permission is strictly prohibited Details given in this document are believed to be correct at the time 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 MP11 0056 FDAUS 0312
27. rgon Argon Argon Helium Helium 75 Argon 25 Argon onl Helium Argon Helium Argon Argon Helium Argon Helium Benefits Used with high frequency AC good stable a gt C good cleaning action Used with high frequency AC good cleanin h increased pe uces penetration during acing minimising dilution R sur Stab Low Stab Stab C to st Inc S an NA THM U Noranr igh ed an aD aD ower penetration D d a igh aD gh ee md ood penetration ood penetration sed with con g action er welding speed netration arc ume e and easy to control arc e and easy to control arc be used for copper nickel eel eased heat input e afc e afc arc ual operation speed automated welding arc speed automatic welding per penetration ll concentrated HAZ nuous high f eq uency AC Good arc stability Good cleaning action Good penetration Good arc stability Deeper penetration Stable arc High speed welding 2 5 Welding wire selection The following table includes the recommended welding consumable for the most commonly welded materials Base material BOC Consumable C Mn and low carbon steels Low Alloy steels 1 25Cr 0 5Mo 2 5Cr 1Mo Stainless Steel 304 304L 316 316L 309 309 C Mn 321 Stabilised grades Aluminium 1000 series 5000 series
28. rofile Loss of gas coverage Acute angle Angular Unsymmetrical bead mis alignment profile l Mis alignment Incomplete i penetration Filler rod removed from gas shield ts movement Tungsten inclusions Tungsten inclusions Electrode contact with the weld pool BOC Smootharc TIG 185 AC DC Operating Manual 17 3 0 TIG Welding of Materials 3 1 Application summary 3 2 CMn steel TIG welding may be used for welding carbon steel but because dat ia ey deposition rates are low it is usually only used for welding sheet and thin CMn steel Direct current DC negative sections for high quality applications small components and root passes Alloyed steel Direct current DC negative of multipass butt joints in plate and pipe Copper and Cu alloys Direct current DC negative Standard DC TIG equipment is normally suitable and DCEN polarity is Nickel and Ni alloys Direct current DC negative usually chosen to provide good workpiece heating Titanium and Ti alloys Direct current DC negative Aluminum and Al alloys Alternating current Only inert or reducing gases should be used for TIG welding and pure Direct current DC negative argon is normally recommended as the shielding gas for steel with Helium Filler rods are usually selected to match the chemical composition and agesium and Mg
29. s damage of costs including but not limited to daily allowances or accommodation and travelling costs Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void NOTE Under the terms of warranty welding torches and their consumables 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 11 3 Warranty Period The warranty is valid for 18 months from date of purchase provided the machine is used within the published specification limits 11 4 Warranty Repairs A BOC approved 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 amp Gear for a directory of BOC approved service providers in your area For more information contact the BOC Customer Service Centre BOC Australia 131 262 contact boc com BOC New Zealand 0800 111 333 customer servicenz boc com BOC Limited 10 Julius Avenue North Ryde NSW 2113 Australia www boc co
30. s 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 S tandard 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 WT A Technical Note No 7 Health and Safety Welding Pub ished by WTIA PO Box 6165 Silverwater NSW 2128 Pho ne 02 9748 4443 8 BOC Smootharc TIG 185 AC DC Operating Manual 2 0 Gas tungsten arc welding GTAW TIG Schematic of the TIG welding process Collet Shielding gas Tungsten electrode Arc TIG filler rod Weld pool Workpiece 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 pool The arc area is shrouded in an inert or reducing gas shield to protect the weld pool and the non consumable electrode The process may be operated autogenously that is without filler or filler may be added by feeding a consumable wire or rod into the established weld pool 2 2 Process Direct or alternating current power sources with constant current output characteristics are normally employed to supply the welding current For DC operation t
31. torch Add filler metal Wi Remove rod Move torch to front of pool Repeat BOC Smootharc TIG 185 AC DC Operating Manual 13 Tungsten tip preparation Tungsten electrode tip shapes and current ranges DCSP EN or DCRP EP ACHP General Purpose Thoriated ceriated and lanthanated ungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes and as such are O Diameter Flat f Max ball typically used for DCSP welding These electrodes maintain a ground I ez Dia E M Max b en A 4 tip shape much better than the pure tungsten electrodes If used on A Ld AC thoriated and lanthanated electrodes often spit Regardless of the gt 000 lt Taper length electrode tip geometry selected it is important that a consistent tip 2 3x Dia i configuration be used once a welding procedure is established Changes Ball tip by arcing on clean metal at low current DCRP EP then slowly in electrode geometry can have a significant influence not only on the increase current to form the desired ball diameter Return setting to AC weld bead width depth of penetration and resultant quality but also on the electrical characteristics of the arc Below is a guide for electrode tip Tungsten grinding preparation for a range of sizes with recommended current ranges Shape by grinding longitudinally never radially Remove the sharp point to leave a truncated point with
32. ts Good arc starts Medium tendency to spit edium erosion rate Low erosion rate Wide current range AC or DC No spitting Consistent arc starts Good stability Lowest erosion rate Widest current range on DC No spitting Best DC arc starts and stability Use on lower current only Spitting on starts Rapid erosion rates at higher currents Low erosion rate Wide current Good stability ange No spitting Consistent arc starts Lowest erosion rate Highest current range No spitting Best DC arc starts and stability 12 BOC Smootharc TIG 185 AC DC Operating Manual 2 7 Welding techniques TIG Welding techniques Vertical Shield A amp Direction of travel Welding Rod 15 30 60 75 lungsten 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 Tungsten Without Filler Rod 2 8 Torch movement during welding Tungsten With Filler Rod Welding direction lt _ L lt Form pool p T A Tilt torch y Move torch to front of pool Repeat Welding direction Form pool LY Tilt
33. uality joints to be made 3 6 Balanced Squarewave The balance on squarewave machines can be adjusted to achieve the desired results Greater amounts of EN create a deeper narrower weldbead and better joint penetration This helps when welding thick material and promote faster welding speeds Greater amounts of EP removes more oxides from the surface but also have a shallower penetration h AC cleaning of the oxide positive cycle and heating occurs on the h aluminium the m must this High purity argon and face oxide fi argon helium shielding gas mixtures can be used The AC output may be conventional sine wave or square wave and many electronic power sources allow the AC waveform to be adjusted and also provide facilities for pre and post gas flow and current slope in and slope out Aluminium welding parameters Plate Thickness mm 1 2 3 4 5 5 6 6 Joint type Square butt Square butt Square butt Square butt Square butt V butt 70 Square butt V butt 70 Tungsten size mm 1 6 1 6 2 4 2 4 2 4 32 3 2 3 2 Consumable Size mm 1 6 3 2 3 2 3 2 3 2 3 2 3 2 32 Current A 75 110 125 160 185 165 210 185 Welding speed mm min 26 21 17 15 14 14 8 10 Gas flow l min 5 6 6 8 10 12 12 12 Alternating current Welding position Downhand Pure Aluminium 20 BOC Smootharc TIG 185 AC DC Operating Manual 3 7 Copper and copper alloys Cleanliness is important when welding copper and all dirt grease and
34. um 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 6 BOC Smootharc TIG 185 AC DC Operating Manual Operator wearing personal protective equipment PPE in safe position Back view of typical cylinder valve Cylinder safety diagram 1 Cylinder valve hand wheel 2 Back plug 3 Bursting disc Ten points about cylinder safety 1 Read 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 3 Guard cylinders against being knocked violently or being allowed to fall 4 Wear 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 flammable gases ri Keep full and empty cylinders separate 8 Keep 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
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