P

For more information on any BOC Industrial product or service call the BOC Customer Service Centre on: AU S T R A L I A

TM

P RO D U C T S T H AT P E R F O R M

131 262
Email: contact@spr.gases.boc.com Website: www.boc.com.au NEW ZEALAND

0800 111 333

Email: customer-service@spr.gases.boc.com Website: www.boc.co.nz

BOC MIG 320R/420R

O P E R AT I N G M A N U A L

BOC Limited
ABN 95 000 029 729

Riverside Corporate Park 10 Julius Avenue North Ryde, NSW 2113 AUSTRALIA

BOC Limited 970 992 Great South Road Penrose, Auckland NEW ZEALAND

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.

IP 20883 AZZAUS 1003

2K

BOC is a trading name of BOC Limited, which is an operating company within The BOC Group, the parent company of which is The BOC Group plc.The stripe symbol and the word BOC are a registered trademark of The BOC Group plc and used under licence by BOC Limited. BOC Industrial is a trademark of BOC Limited. BOC Limited 2003. Reproduction without permission is strictly prohibited.

Welcome to a better way of welding

Congratulations on purchasing a BOC 320R/420R MIG Machine The BOC MIG range are products that perform with reliability and the backing of a leading welding supplier. This manual provides the basic knowledge required for MIG welding, as well as highlighting important areas of how to operate the machine. By following these steps, your BOC MIG machine will provide trouble-free service. Access to a wealth of experience and technical information accumulated over the years makes the BOC range of equipment a world leader. BOC equipment and technical support is available through our national BOC Customer Service Centre or contact your local Gas & Gear outlet.

Contents
1. 1.0 1.1 1.2 1.3 1.4 2. 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3. 3.0 3.1 3.2 4. 5. 6. Safety Precautions Health Hazard Information Personal Protection Electric Shock Use of Gas Cylinders User Responsibility The MIG Welding Process MIG Welding How the Process Works MIG Welding Equipment The Modes of Metal Transfer Power Source Voltage Selection Wire Feed Roll Tension Duty Cycle Shielding Gases Overview General Instructions for Pressure Regulators GMAW Shielding Gas Selection Chart Plant Specications Plant Contents Operating Controls Diagram A BOC MIG 320R & MIG 420R Wire Speed Control Thermal Overload Indicator Power On/Off Switch 2T & 4T Trigger Function Polarity Selection Positive Cable Socket & Negative Cable Socket 6.6 Control Fuse Inductance Setting Operation of Cooling Fan Burn Back Control/Inch Control 6.7 6.8 6.9 15 15 16 16 16 16 14. Glossary 31 11.Trouble Shooting How to Rectify GMAW & Machine Faults 12.Terms of Warranty 28-29 30 14 15 15 15 15 10. 10.0 10.1 10.2 10.3 Periodic Maintenance Wire Feed Cables Power Source Consumable Parts 27 27 27 27 10 10 11 12 13 6 6 7 7 9 9 9 9 4 4 5 5 5 7. 7.0 7.1 7.2 7.3 8. 8.0 8.1 8.2 8.3 8.4 9. 9.0 BOC Wire Feeder Diagram B WF2 & WF4 Wire Feeder Controls 18 Diagram C WF2 & WF4 Internal Diagram Diagram D WF2 Wire Feeder Spare Parts Diagram E WF4 Wire Feeder Spare Parts BOC MG42i Gun Features Specications Diagram F MG42i BOC MG42i Gun Spare Parts BOC MIG Machine Optional Extras 22 22 22 23 23 19 20 21

Installation of Power Source Transport & Lifting of the BOC 320/420R MIG Machines 9.1 Machine Work Site 9.2 Welding & Return Cables 9.3 Connection to Mains Power 9.4 Mounting & Locking of Wire Spool 9.5 Automatic Wire Feed to MIG Gun 9.6 Fitting the Spool 9.7 Adjustment of Feed Roll Tension 9.8 Adjusting Wire Hub Brake 9.9 Regulator 9.10 Shielding Gas 9.11 Gas Cylinder

24 24 24 24 24 25 25 26 26 26 26 26

BOC Customer Service Centre AU S T R A L I A

6.0 6.1 6.2 6.3 6.4 6.5

131 262
Email: contact@spr.gases.boc.com Website: www.boc.com.au NEW ZEALAND

0800 111 333

Email: customer-service@spr.gases.boc.com Website: www.boc.co.nz

6.10 Voltage Switch Selection

1.2 Electrical Shock

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 qualied 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. When necessary, vacuum inside of wire feeder compartment.

1. Safety Precautions
1.0 Health Hazard Information
The actual process of GMAW (MIG) is the 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 manufacturers recommendations as electric shock can kill. Eyes The MIG process produces 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. Shielding Gases (Carbon Dioxide or inert gases) in high concentrations when working in conned spaces may lead to dangerous low levels of oxygen, resulting in asphyxiation. Ventilation and fume extraction should be used to minimise exposure levels in accordance with Australian Standards.The operator should be trained to work in a manner that minimises the exposure.

1.1 Personal Protection

Respiratory Conned 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. Eye Protection A welding helmet with the appropriate welding lter for the operation must be worn.Welding arc and the reective arc ash will hurt unprotected eyes. Protective welding screen and goggles should be provided for others working in the same area. Recommended lter shades for arc welding Less than 150 amps 150 to 250 amps 250 to 300 amps 300 to 350 amps Over 350 amps
*Use one shade darker for aluminium

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.

1.3 Use of Gas Cylinders

Always use the recommended shielding gas for the application. Read labels and Materials Safety Data Sheet (MSDS) before use. Store upright and use in well ventilated, secure areas away from pedestrian or vehicle thoroughfare. Guard cylinders against being knocked violently or allowed to fall. Wear safety shoes and gloves when handling cylinders. Always move cylinders securely with an appropriate trolley. Keep in a cool well ventilated area away from heat sources, sources of ignition and combustible materials, especially ammable gases. Keep full and empty cylinders separate. Keep oil and grease away from cylinders and valves. Never use force when opening or closing valves. Dont repaint or disguise markings and damage, if damaged return to BOC immediately. Keep head and face away from the cylinder valve when opening. Read and follow instructions on compressed gas cylinders and associated equipment AS2030 Parts1&2. Further details regarding these steps and other actions you can take for safer storage and handling refer to BOC Limited.

STOP
PLEASE NOTE that under no circumstances should any equipment or parts be altered or changed in any way from the Standard specication without written permission given by BOC.To do so, will void the Equipment Warranty.

Shade 10* Shade 11* Shade 12 Shade 13 Shade 14

Clothing Suitable clothing must be worn to prevent excessive exposure to UV radiation and sparks. Protective gloves, spats, apron and welding shield are recommended.

Further information can be obtained from the Welding Technology Institute of Australia (WTIA). Health and Safety in Welding TN7. Published by WTIA, PO Box 6165 Silverwater NSW 2128 Phone (02) 9748 4443. Fume Minimisation Guidelines www.wtia.com.au

2.The MIG Welding Process

2.0 MIG Welding
MIG (Metal Inert Gas) welding means that the shielding gas used is inert, it does not chemically combine with the welding materials.The purpose of shielding gas is to protect the arc process against the defective effects of air as well as to cool down the welding gun. In steel welding, the choice of shielding gas inuences the spatter amount, productivity, penetration, welding speed as well as the seam prole. The MIG welding process is very popular in the fabrication and construction industries because of its advantages over other types of welding. MIG welding is usually carried out with a handheld gun as a semi-automatic process.The MIG process can be suited to a variety of job requirements by choosing the correct shielding gas, electrode (wire) size, and welding parameters. Welding parameters include the voltage, travel speed, arc (stick out) length and wire feed rate. The arc voltage and wire feed rate will determine the ller metal transfer method. This application combines the advantages of continuity, speed, comparative freedom from distortion and the reliability of automatic welding with the versatility and controllability of manual welding.The process is also suitable for mechanised set-ups, and its use in this respect is increasing. MIG welding can be done using solid wire, ux cored, or a copper coated solid wire electrode. The shielding gas or gas mixture may consist the following: argon carbon dioxide argon and carbon dioxide mixtures argon mixtures with oxygen or helium mixtures Each gas or gas mixture has specic advantages and limitations. Other forms of MIG welding include using a ux-cored continuous electrode method using CO2 shielding gas, or using a self-shielding uxcored wire requiring no shielding gas as the ux creates its own shielding gas.

2.2 MIG Welding Equipment

The equipment used for MIG welding consists of: power source (transformer/rectier or inverter) wire feed unit (designed to allow the wire to feed freely and evenly) wire rolls regulator (adjusts and maintains constant gas pressure) ow meter (adjusts and maintains constant gas ow rate) gas cylinder gas shielding (protects weld from atmospheric contamination) contact tip

end of the electrode. A high short-circuiting frequency gives low heat input. Dip transfer occurs between 70-220A, 14 23 arc volts. It is achieved using CO2 and argon based gases. ii. Spray transfer In spray transfer, metal is projected by an electromagnetic force from the wire tip in the form of a continuous stream of discrete droplets about the same size as the wire diameter. High deposition rates are possible and weld appearance and reliability are good. Most metals can be welded, but the technique is limited generally to plate thickness greater than 6mm. Spray transfer, due to the tendency of the large weld pool to spill over cannot normally carry out Positional welding.The main exception is aluminium and its alloys where, primarily because of its low density and high thermal conductivity, spray transfer in position can be carried out. The current ows continuously because of the high voltage maintaining a long arc and shortcircuiting cannot take place. It occurs best with argon based gases. iii. Globular transfer Metal transfer is controlled by slow ejection resulting in large, irregularly shaped globs falling into the weld pool under the action of gravity. CO2 gas drops are ung about haphazardly, while with argon based gases the drops are not quite as large and are transferred in a more axial direction.There is a lot of spatter, especially in CO2, resulting in greater wire consumption, poor penetration and poor appearance. Globular transfer occurs between the dip and spray ranges.This mode of transfer is undesirable for normal welding applications and may be corrected when encountered by either decreasing the arc voltage or increasing the amperage. Globular transfer can take place with any electrode diameter.
7

2.3 The Modes of Metal Transfer

The mode or type of metal transfer depends upon the current, arc voltage, electrode diameter and type of shielding gas used. In general, there are four modes of metal transfer. These are: i. Dip transfer Also known as short-circuiting arc or short-arc, this is an all-positional process, utilising low heat input. The use of relatively low current and arc voltage settings causes the electrode to intermittently short-circuit with the weld pool at a controlled frequency. Metal is transferred by the wire tip actually dipping into the weld pool, and the short-circuit current is sufcient to allow the arc to be re-established.This short-circuiting mode of metal transfer effectively extends the range of MIG welding to lower currents so thin sheet material can readily be welded. The low heat input makes this technique well suited to the positional welding of root runs on thick plate, butt welds for bridging over large gaps and for certain difcult materials where heat input is critical. Each short-circuit causes the current to rise and the metal fuses off the

2.1 How the Process Works

MIG welding embraces a group of arc welding processes in which a continuous electrode (the wire) is fed by powered feed rolls (wire feeder) into the weld pool. An electric arc is created between the tip of the wire and the weld pool. The wire is progressively melted at the same speed at which it is being fed and forms part of the weld pool. Both the arc and the weld pool are protected from atmospheric contamination by a shield of inert non-reactive gas, which is delivered through a nozzle that is concentric with the welding wire guide tube.
wire spool drive rolls

contact tube gas nozzle shielding gas workpiece

+ power source

Figure 1: Schematic interpretation of MIG Welding

iv. Pulsed transfer Pulsed arc welding is a controlled method of spray transfer, using currents lower than those possible with the spray transfer technique, thereby extending the applications of MIG welding into the range of material thickness where dip transfer is not entirely suitable. The pulsed arc equipment effectively combines two power sources into one integrated unit. One side of the power source supplies a background current which keeps the tip of the wire molten, the other side producing pulses of a higher current which detach and accelerate the droplets of metal into the weld pool.The frequency of transfer of these droplets is regulated primarily by the relationship between the two currents. Pulsed arc welding occurs between 50-220A, 23 35 arc volts. It occurs only with argon and argon based gases and enables welding to be done in all positions.

2.4 Power Source

MIG welding heat is generated by the ow of current though the gap between the end of the wire electrode and the workpiece. A voltage forms across this gap which varies with the length of the arc.To produce a uniform weld, the welding voltage and arc length must be maintained at a constant value by: feeding the wire into the weld zone at the same rate at which it melts or; melting the wire at the same rate it is fed into the weld zone The constant voltage power supply was developed for MIG welding because of the need for better arc control.The constant voltage (CV) welding power supply has a relatively at volt/ampere characteristic.This means that a pre-set voltage level can be held across its range.

2.6 Wire Feed Roll Tension

Most wire feed systems consist of two or four feed rolls.They are a combination of a driven roll with a groove machined into its circumference, and pressure rolls that put physical pressure on the wire.When the drive roll rotates, the wire is fed through the rolls to the gun. With the wire feed running, adjust the feed roller pressure so that the wire reel can be stopped by slight pressure. If the roller pressure is too light the wire will feed erratically.Too high a pressure will cause twisting of the consumable wire and aking of the protective copper coating which will clog the wire liner.
TENSIONER

Figure 2: Dip Transfer A short-circuiting arc in progress

Figure 3: Spray Transfer

Figure 4: Globular Transfer

2.5 Voltage Selection

Welding voltage is selected by a switch or switches on the front panel.The higher the number or combination of numbers on each switch will give a higher welding voltage (see voltage switch selection table).Voltage is selected according to the material, thickness, wire diameter and type of weld required i.e. short or spray arc. Warning: Never switch voltage selector when welding as this will damage the switch(s).

2.7 Duty Cycle

Most welding equipment is tested and rated at a certain duty cycle.This duty cycle determines a machines output limitations in current and time to avoid internal components from overheating and is based on a 5 or 10 minute cycle.The BOC MIG 320R has a duty cycle of 320 amps at 50%.The BOC MIG 420R has a duty cycle of 420 amps at 50%.

Figure 5: Pulsed Transfer

Summary of MIG transfer modes

TRANSFER METHOD WELDING POSITIONS OPERATING RANGE VOLTS AMPS WIRE DIAMETER USES

Short arc (dip) Globular arc Spray arc

All Flat or horizontal (llets) Flat or horizontal (llets)

13 to 23 20 to 26 24 to 40

60 to 200 200 to 280 210 to 410

0.6 to 1.2mm All 0.8 to 1.6mm

Light gauge material Between dip and spray Material over 5mm
COURSE STEPS FINE STEPS

3. Shielding Gases
3.0 Overview
Shielding gases for MIG welding are important for keeping the arc stable and protecting the molten weld metal from contamination during welding. The major function of a shielding gas is to surround the weld zone with a protective shroud of non-reactive shielding medium. This removes harmful elements from the atmosphere (oxygen, nitrogen gas) which would give a poor quality weld deposit if they contacted the molten metal. Different shielding gases or gas mixtures are used when welding various metals; for example, pure argon is commonly used for the welding of aluminium and copper. Stainless steel requires an argon or argon oxygen (O2) and helium mixture with a maximum of 3.6% carbon dioxide (CO2) content and carbon and low alloy steels can be welded with carbon dioxide or argon-oxygen-CO2 mixtures. There are, however, certain points, which must be explained to show the effects of mixing of gases on the type of bead and penetration. Argon gives a smooth wide spread whilst CO2 adds to penetration.The addition of small percentages of oxygen provides better wetting action reducing the surface tension of the weld. Careful consideration of various mixtures has led to a range of gases to suit many applications, and the choice of shielding gas requires due care. Typical shielding gases used for this process include: argon/oxygen/carbon dioxide carbon dioxide argon/carbon dioxide mixtures argon helium mixtures
10

3.2 GMAW Shielding Gas Selection Chart

Light Steel The recommended ow rate for argon and argon mixtures is 14 L/min (14 litres per minute) and 18 L/min (18 litres per minute) for CO2 when used with a heated regulator. Post ow of the shielding gas is needed to protect the solidifying weld metal from contamination from oxygen, nitrogen and water vapour in the atmosphere.
APPLICATION ARGOSHIELD MODE BENEFITS

Sheet steel Light gauge steel

Argoshield 40 Argoshield Light

Spray/DIP Spray/DIP

Clean and fast low bead prole Economical and fast for general light work

High quality

Argoshield 54

DIP

Excellent nish on sheet steel, minimal clean up electroplating quality

3.1 General instructions for pressure regulators

PLEASE NOTE It is important that you read and understand the operating instructions supplied with the regulator before using it. Regulator connection 1. Fit the regulator bull-nose into the cylinder valve and tighten the nut (do not over tighten). 2. Turn the regulator knob in an anti clockwise rotation, so that there is no pressure on the regulator diaphragm.This is the fully off, no-ow position. 3. Attach hose nut/nipple to the regulator outlet. Setting the regulator 1. Open the valve of bottle slowly. 2. The high pressure gauge will show the pressure in the bottle. 3. Adjust the regulator knob until the desired pressure is achieved on the low pressure gauge (12 to 20 L/min usually). 4. Pull the torch trigger to simulate a welding condition, and readjust the regulator knob to the desired pressure that will be required while welding (it is normal for the gas delivery gauge to drop back while in use due to pressure drop when in the static position). Close the valve of the cylinder after welding has stopped. If the machine will be out of use for a long period of time, you should close the regulator knob to act as a secondary valve.

Heavy Steel
APPLICATION ARGOSHIELD MODE BENEFITS

Welding to AS1554 Standard Positional welding

Argoshield Universal

DIP/Spray

Excellent penetration and speed.Weld to x-ray quality.

Argoshield 52

DIP

Stiff arc with low spatter, excellent penetration

Stainless and Low Alloy Steel

APPLICATION ARGOSHIELD MODE BENEFITS

Economy

Stainshield

DIP

Stiff arc with low spatter, excellent penetration

High speed

Argoshield 61

DIP/Spray

Excellent penetration and nish. Also suitable for positional welding

Non Ferrous Welding

APPLICATION ARGOSHIELD MODE BENEFITS

Sheet aluminium (up to 6mm) Braze welding bronze to other metals Light gauge Heavy gauge (over 10mm)

BOC Welding Argon

Spray

Economical

Specshield Copper Alushield Light Alushield Heavy

Spray Spray Spray

Increased performance High speed clean nish Deep, wide fusion. High deposition rates
11

4. Plant Specications
DESCRIPTION

5. Plant Contents
MIG 320R WF2: B621532001 WF4: B621532002 380-415 50/60 3 14 20 5 40-320 50% @ 320A 15.7-41.1 40 2 8 MG42i/4 0-18 MIG 420R B621542001 380-415 50/60 3 23 25 5 40-420 50% @ 420A 16.5-48.9 56 2 8 MG42i/4 0-18 or 25 0.6-1.6 0.8-1.6 0.8-1.6 108 77x42x98 The packages include:

Part number Supply Voltage (V) Frequency (Hz) Phase Rated primary current (A) Supply Fuse (recommended A) Primary cable length (m) Welding Current (Amps) Duty Cycle Output Voltage OCV (V) Voltage Steps Inductance Settings Remote interconnection cable length (m) BOC gun/length (m) Wire Feed Speed (m/min) Wire Diameter (mm) Solid Soft Flux cored Weight Power Source (Kg) Dimensions HxWxL (cm)

BOC MIG 320R (Part No. B621532001)

MIG gun MG42i Euro t 4 metre standard gun (Part No. BMG4202/4) Power source 320R WF2 Wire Feeder (Part No. B621720001) WF4 optional (Part No. B621740001) BOC 6000 Argon regulator 45 L/m (Part No. 105206) Digital volt/amp meter Gas hose Under carriage Work lead 35mm2 Primary cable 5 metre Wheel kit

BOC MIG 420R (Part No. B621542001)

BOC MIG gun MG42i Euro t 4 metre standard gun (Part No. BMG4202/4) Power source 420R WF4 Wire Feeder (Part No. B621740001) BOC 6000 Argon regulator (Part No. 105206) Digital volt/amp meter Gas hose Under carriage Work lead 50mm2 Primary cable 5 metre Wheel kit

0.6-1.2 0.8-1.2 0.8-1.6 97 77x42x98

12

13

6. Operating Controls
6.0 Diagram A BOC MIG 320R and MIG 420R (MIG 420R shown)
ITEM DESCRIPTION

6.1 Wire Speed Control

Wire speed control is obtained by adjustment of the knob mounted on the front panel.The maximum wire speed is 18 m/min.The WF4 can be increased to 25 m/min by replacing the drive gear. Use material number B4265250 (see Diagram E, page 21).

3 1 2

1 2 3 4 5 10 11 6 7 8 9 10 11 12 13

Weld mode 2T/4T/spot time Spot/stitch timer Wire speed control Main power on/off switch Thermal overload indicator Voltage switch course Voltage switch ne Negative cable socketinductance setting Positive cable socket Euro Gun connection Gun holder Control cable socket Control fuse

4-sequence (4T) Gas ow starts, when the gun switch is pressed. When the switch is released, wire feed starts and welding begins.When the gun switch is pressed again, wire feed stops and when the switch is released, gas ow stops.The duration of wire feed can be preset with the Timer control. Spot welding Gas ow and wire feed starts, when the gun switch is pressed and stops automatically according to Timer setting or when the gun switch is released. Note: The procedure does not start if Timer selection is set on 0-area. Timer potentiometer The duration of welding can be adjusted with Timer potentiometer.Wire feed and gas ow will stop automatically after a preset time, if they are not stopped before that manually from gun switch.

6.2 Thermal Overload Indicator

A yellow light on the front panel indicates that the machine is overloaded and will shutdown automatically.The cooling fan will continue to run and the overload will reset automatically after cooling down. Always check air circulation has not been obstructed.When the light goes off you may continue.

4 5

6.3 Power On/Off Switch

In the O position all controls of the machine are without power. Illuminated when ON.

6 7

6.5 Polarity Selection Positive Cable Socket and Negative Cable Socket
For welding with Steel, Stainless Steel (SS), or Aluminium (Al) solid wires (gun positive), place the dinse plug in the positive (+) socket and lock by twisting clockwise.The work lead is then connected to the negative (-) and locked. For gasless ux cored wires, reverse polarity (Gun negative) connect the dinse plug to the negative plug & lock.The work lead is then connected and locked to the positive (+) plug (see page 14).

13 8

6.4 2T and 4T Trigger Function

Shielding gas ow and wire feed are regulated from the gun switch.The suitable procedure is selected with the welding procedure selection switch, which has three different positions: 2-sequence (2T) Gas ow and wire feed starts, when the gun switch is pressed and stops when the switch is released.The duration of wire feed can be preset with the Timer control.

12 9

6.6 Control Fuse

To prevent possible overload or system short circuit a control fuse (8A) has been installed and is located on rear of machine. Fuses are labelled T8A.
15

14

6.7 Inductance Setting

The BOC MIG 320R/420R has two negative connectors on the front panel marked I and II and are used for connecting the work cable or gun polarity cable depending on the polarity required (see (6.5) polarity selection). Connecting to either connection will affect the amount of inductance in the welding circuit which will change the arc characteristics when welding in the short arc range.I will have less inductance and will allow a cooler arc with slightly more spatter and is generally used for thinner materials or when using CO2 shielding gas.II has more inductance that creates a smoother arc with more heat input and is suited to thicker material, aluminium and stainless applications. It is recommended that both settings are used to determine to best connection for each weld application.

6.8 Operation of Cooling Fan

The cooling fan will automatically turn on after 30 seconds of operation and will continue for a period of ve (5) minutes after welding has ceased or when the thermal overload releases. Air intake is via the rear panel. WARNING Do not switch off main power to machine until fan has stopped.

BOC MIG 420R OPEN CIRCUIT VOLTAGE STEPS (56 STEPS)

FINE SWITCH COURSE SWITCH

1 LOW 15-28V 1 2 3 4 5 6 7 HIGH 28-48V 1 2 3 4 5 6 7 29.5 29.8 30.3 30.7 31.2 31.7 32.2 16.5 16.9 17.1 17.3 17.6 18.0 18.2

2 18.6 18.9 19.2 19.6 20.0 20.3 20.7

3 21.0 21.5 22.0 22.3 22.8 23.3 23.7

4 24.3 24.9 25.5 26.0 26.9 27.6 28.2

6.9 Burn Back Control/Inch Control

The burn back and inch controls are located inside the wire compartment of the machine.

32.8 33.4 33.9 34.5 35.1 35.8 36.4

37.1 37.9 38.7 39.3 40.2 40.9 41.7

42.7 43.7 44.7 45.7 46.7 47.8 48.9

6.10 Voltage Switch Selection

The table below indicates the open circuit voltages for each setting. BOC MIG 320R OPEN CIRCUIT VOLTAGE STEPS (40 STEPS)
FINE SWITCH COURSE SWITCH

WARNING Do not adjust the voltage setting while welding. 3 23.6 24.1 24.6 25.1 25.7 26.2 26.8 27.8 28.4 29.2 4 31.5 32.4 33.3 34.2 35.0 36.1 37.2 38.4 39.7 41.1

1 1 2 3 4 5 6 7 8 9 10 15.7 16.0 16.2 16.5 16.7 16.9 17.2 17.5 17.8 18.0

2 18.9 19.2 19.5 19.9 20.2 20.6 21.0 21.4 21.8 22.2

WARNING Do not adjust the voltage setting while welding.

16

17

7. BOC Wire Feeder

7.0 Diagram B WF2 and WF4 Wire Feeder Controls (WF4 shown)
(WF2 Part No. B621720001,WF4 Part No. B621740001) 6

7.1 Diagram C WF2 and WF4 Internal Diagram

1 2 3

1 2

3 4 5

4 5

WF4

1 2
ITEM DESCRIPTION ITEM DESCRIPTION

1 2 3 4 5 6

Wire Speed Control Weld Mode 2T/4T/Spot time Spot/stitch timer Euro Gun Connection Pull/Push Control Optional Gun holder

1 2 3 4 5 6

Wire Inch Burnback Control Feed Roll Tensioner Wire Inlet Guide Feed Roll Securing Knob Spool hub

3 4 5

WF2

18

19

7.2 Diagram D WF2 Wire Feeder Spare Parts

Guide Tube
WIRE DIAMETER PART NO.

7.3 Diagram E WF4 Wire Feeder Spare Parts

Guide Tube
WIRE DIAMETER PART NO.

FE MC FC SS AL

0.6 0.8mm 0.9 1.6mm 0.8 1.6mm

B3134140 white B3133700 orange B3134290 silver

FE MC FC SS AL

0.6 0.8mm B3134140 white 0.9 1.6mm B3133700 orange 0.8 1.6mm B3134290 silver

B3134290 orange B3134300 silver

B4285900 brass

B4267220 plastic

B4102283 plastic

B4265240

B4265240 0-18 m/min B4265250 0-25 m/min

Feed Roll
WIRE FEED ROLL TYPE

0.6mm /0.8mm B3133810 white

0.9 1.0mm/1.2mm B3133210 red B3133940 red B3133960 red

1.4mm/1.6mm B3133820 yellow B3133990 yellow Feed Roll

WIRE FEED ROLL TYPE

FE SS FE FC AL

Plain Knurled U-groove

0.6mm/0.8mm B3133810 white

0.9 1.0mm/1.2mm B3133210 red B3133940 red B3133960 red

1.4mm/1.6mm B3133820 yellow B3133990 yellow

FE SS AL FE FC AL

Plain Knurled U-groove

20

21

8.3 BOC MG42i Gun Spare Parts (refer to Diagram F, page 22)

8. BOC MG42i Gun

8.0 Features
The BOC welding gun range has been selected to match the capabilities of the BOC MIG range.The gun selections for each machine will optimise the machines performance characteristics to ensure reliability and troublefree operation. Colour coding of the gun consumables and wire feed rolls are to ensure parts match and for quick identication when trouble-shooting wire feed problems. Other features of the welding gun range include: Ergonomic design for improved operator comfort Swivel head for exibility Lightweight European design Cables of varying length (optional) Euro quick connection Trigger protection Colour coded sizing to ensure correct drive rollers/liner match

DIAGRAM NO.

DESCRIPTION

PART NO.

Gas nozzle standard Gas nozzle long Gas nozzle conical

B4255530 B4255530E B4273510 B4248710 B9580122 B9580121 B9580123 B9580124 B9580125 B9580126 B426964001 B4270290 B4270750 B4270780 B4286450 B4188577 B4188587 B4188590 B4300850 B4302690 B4302710 B4290120 B4305240 B4302780 B3133490 B9580159

2 3

Insulating bush Contact tip 0.8mm/M8 Contact tip 0.9mm/M8 Contact tip 1.0mm/M8 Contact tip 1.2mm/M8 Contact tip 1.4mm/M8 Contact tip 1.6mm/M8

4 5 6

Contact tip adapter M8 Insulating ring Gooseneck 45 degree standard Gooseneck 60 degree long Gooseneck 45 degree short

8.1 Specications
PART NO. WELDING GUN / CABLE WIRE SIZES

(mm)

DUTY CYCLE

(m) 0.8 1.6

BMG4202/4

MG42i/4

AR, AR + CO2 350A/60%

CO2 420A/60% 7

Liner steel 0.6 0.8mm/4m (white) Liner steel 0.9 1.2mm/4m (red) Liner steel 1.4 1.6mm/4m (yellow) Liner DL Teon 0.8 1.6mm/4m AL (silver) Liner DL Teon 0.8 1.0mm/4m SS (silver) Liner DL Teon 1.2 1.6mm/4m SS (silver)

8.2 Diagram F MG42i (Part No. BMG4202/4)

8 9 10 11 12

Trigger switch Handle Retaining ring Cable support Euro connection block

8.4 BOC MIG Machine Optional Extras

11 10 9 8 6 5 4 3 2 1
DESCRIPTION

Push/Pull Gun KMW Sync. Unit Remote Wire Feeder Hanging Bracket

MIG 320R B6219100 B3135870

MIG 420R B6219100 B3135870

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9. Installation of Power Source

9.0 Transport and Lifting of the BOC 320R or 420R MIG Machines
NOTE Never transport the BOC MIG on its side. Never use the BOC MIG on its side. The BOC MIG weighs between 100 126kg. NOTE Never load welding cables beyond their design capabilities. All electrical contact points should be clean and free of oil, grease and rust.

9.5 Automatic Wire Feed to MIG Gun

WARNING! Keep ngers away from moving drive rolls when feeding the wire. Prior to loading, ensure that the diameter of the wire matches the feed rollers. Repositioning the washer from either side of the drive roller can change the feed roller wire diameter groove. Release wire from spool and at the same time, maintain pressure to avoid wire spill from reel. Inspect the wire end for sharp edges, and if necessary, cut the end off with pliers to prevent damage to liner. Ensure wire is clean to ease wire feeding. Straighten approximately 20cm of wire and feed through to the back of the inlet guide towards the feed rolls. Do not release feed roll pressure. Press wire inch switch. Feed the wire through to the feed roll ensuring that wire is in the feed roll grooves. Continue to feed wire through the gun to the contact tip.
FEED ROLL SELECTING WASHER FEED ROLL

9.6 Fitting the Spool

NOTE The BOC 320/420R is designed for use with 300mm diameter spools with a 50mm diameter hub. 1. Select the correct feed roll groove and size from the table on pages 20-21 to suit the wire in use. BOCs 320/420R comes with the 0.9mm/1.2mm Plain V Groove feed roll as standard. Reposition washer if necessary. 2. Fit the spool so that the wire feeds off the top of the spool towards the wire feed mechanism. 3. Ensure that the spool locking pin locks the spool in place. 4. Turn the locking knob 90 to lock in place. WARNING! Hold the wire to prevent it from coming off the spool. Make sure the wire is free of burrs & sharp edges before feeding. 5. Carefully release the wire end to free it from the spool. 6. Cut wire back to remove any twists or bends.

9.3 Connection to Mains Power

The BOC 320R and 420R come complete with primary power cable. A qualied electrician must be used to t the primary plug of suitable size.

9.1 Machine Work Site

The BOC MIG machines must be located on a horizontal and dry base.The area must have good ventilation and be free of dust and other air blown hazards. Always allow free space at the front of machine as well as at the rear to allow adequate air circulation through the machine. Protect the machine from rain and temperatures over 30C in direct sunlight. Always ensure that the BOC MIG machine cooling air ducts are clean and unrestricted.

9.4 Mounting and Locking of Wire Spool

Release the locking tabs on the hub by turning the locking knob to the OPEN position. Mount the spool in place. Note the rotation from the direction of spool.Turn knob to CLOSED/ LOCKED position. NOTE Check ller wire spool for no protruding parts which could rub against chassis or door of wire feeder unit. Dragging parts could expose chassis of wire feeder unit to a short circuit of welding voltage.

9.2 Welding and Return Cables

The table shown below is typical loading capacities of rubber insulated copper cables at ambient temperature 25C and a conductor surface temperature 90C.
CABLE CROSS SECTIONAL AREA DUTY CYCLE

SECURING KNOB

PLACEMENT OF GROOVE

7. Straighten about 10cm of the free end. 8. With the Feed Roll tensioner released, gently feed the wire through the inlet guide and the feed roll. 9. Hand feed 30cm of wire into the MIG gun cable. 10. Ensure the wire is located in the Feed Roll groove and then close the Feed Roll tension mechanism. 11. Adjust Feed Roll tension. 12. Remove the gun nozzle and contact tip when feeding the wire to avoid jamming.

100%

60%

30%

16mm2 25mm2 35mm2 50mm2

146 A 193 A 239 A 304 A

187 A 245 A 310 A 392 A

263 A 351 A 438 A 555 A

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9.7 Adjustment of Feed Roll Tension

Adjust the tension of the feed rolls via the tensioner to promote smooth, even wire feed. NOTE Excessive pressure will damage the wire coating and increase feed roll wear.
TENSIONER

9.9 Regulator
Refer to Operating Instructions supplied with the BOC Regulator and connect the hose to the Regulator hose nipple.The regulator supplied with the 320/420R machines is the BOC 6000 Argon Regulator (Part No. 105206).

10. Periodic Maintenance

The working environment or amount of use the machine receives should be taken into consideration when planning maintenance frequency of your BOC MIG welder. Preventative maintenance will ensure troublefree welding and increase the life of the machine and its consumables.

10.2 Power Source

Check electrical connections of the unit at least twice a year. Clean oxidised connections and tighten. Inner parts of the 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 these repairs.

10.0 Wire Feed

Part No. 105206

9.8 Adjusting Wire Hub Brake

Hub brake adjustment is obtained by adjusting the tensioning nut located in the centre of the hub.This is behind the spool locking knob, that can be removed by pulling the locking knob out. Wire tension should be enough to stop the reel from unwinding when the motor stops, but low enough not to overload the wire feeder motor and gearbox.

9.10 Shielding Gas

Check with a BOC Gas & Gear or agent/distributor for the correct BOC shielding gas. Suggested gas ow is 15 20 litres per minute.

Worn wire feed rolls and guide tubes should be replaced. The wire guide tube should be set as near as possible to the feed rolls but without touching them. Check spool brake adjustment. Check electrical connections. Loose connections must be tightened. Clean dirt and dust from unit. If using compressed air wear eye protection.

10.3 Consumable Parts

Regular replacement of consumable parts is recommended for trouble-free welding. These parts include: conduits contact tips gas nozzles For the full range of replaceable spare parts, see page 23.

10.1 Cables 9.11 Gas Cylinder

Always chain cylinder to trolley or upright xture. Never transport cylinder mounted to machine. Always remove before lifting. Open cylinder valve slowly. Never place your face over valve when cracking cylinder. Check condition of cables and connections daily. Do not use faulty cables! Check mains cable condition to ensure they are safe. Any repairs on the mains cable must be carried out by authorised personnel only.

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11.Trouble Shooting
How to Rectify GMAW and Machine Faults
FAULT POSSIBLE CAUSE REMEDY

FAULT

POSSIBLE CAUSE

REMEDY

Lack of fusion Excessive spatter

Voltage too low Incorrect voltage setting Incorrect shielding gas Insufcient inductance Blocked gas nozzle

Increase voltage Readjust voltage setting Check selection Increase inductance if possible Clean nozzle regularly and spray with an anti-spatter

Mains power on but no welding power

Control fuse blown Fault in control circuit of Gun

Replace fuse contact BOC for service Check Gun control plugged in, repair switch in Gun handle Close switch Replace fuse Reset breaker Repair connection Replace fuse contact BOC for service Clean or replace if necessary Weld cracking Irregular weld shape

Current too high for selected voltage Reduce wire feed speed Excessive stick out Wire wander Incorrect shielding gas Travel speed too slow Excessive gas ow Dirty work piece, i.e. grease, paint scale, rust Weld beads too small Weld too deep Contact tip closer to work Replace contact tip Check selection Increase speed Set to 15-20 L/min Clean and degrease prior to welding Slow wire speed down Reduce voltage and wire feed speed Revise setting procedure Decrease voltage Fans starts 30 sec after start of weld and continues for 5 min after end of weld Set to 15-20 L/min (Argoshield) more if windy position Clean work thoroughly Reduce voltage Check gas connections Set to 15-20 L/min Clean nozzle and regularly spray with an anti-spatter Check selection

No mains power on machine

Power supply switch open Primary fuse blown Open circuit breaker Disconnection in primary circuit

Mains power on, no wire feed but contractor operates when trigger is actuated (clacking sound in power source)

Control fuse blown Wire stuck in liner guide or contact tip Poor or no contact between work piece and earth clamp Worn or dirty contact tip Worn wire guides Wire spool runs stify Worn, dirty, kinked conduit

Wire feeds but arc wont strike Erratic stop start wire feeding causing uneven welding conditions

Inspect clamp and work area ensure good contact Replace contact tip Replace and align Reduce tension on spool Clean or replace Increase heat input Replace gas Check and tighten connection Contact BOC for service Increase speed Raise Gun angle Reduce voltage Increase wire feed speed Renew contact tip Shorten stick-out Widen preparation Porosity Fan not working

Highly restrained weld Excessive voltage Fan controlled by control card

Cold weld puddle

Incorrect machine settings Incorrect shielding gas Bad connection Faulty diode

Insufcient shielding gas Dirty work piece Arc voltage too high Air entering into gas shielding system Excessive gas ow rates Spatter on gas nozzle

Undercutting

Speed too slow for current Gun angle too low Voltage too high

Lack of penetration

Current too low Inconsistent current pick up Stick-out too great Joint preparation too narrow

Wrong wire analysis

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12.Terms of Warranty
BOC will provide a warranty to the initial end user of BOC welding equipment as covered by the terms and conditions below. BOC will repair or replace at its option any parts or components that fail due to defects in material or manufacture within the warranty period. All warranty work must be carried out by an authorised BOC service provider, using genuine parts and approved procedures.The warranty is affected on the date of sale to the initial end user. Verbal promises that do not comply with terms of the warranty are not binding on the warrantor. Limitations on Warranty The following conditions are not covered under this warranty: problems due to natural wear and tear; non-compliance with operating and maintenance instructions; connection to incorrect or faulty voltage supply (including voltage surges outside equipment specications); incorrect gas supply or pressure; transport or storage damage; damage due to re and other natural causes i.e. lightning or ood.This warranty does not cover freight, travel and insurance costs these costs are the responsibility of the end user. This does not restrict or modify any warranties that are imposed by any statute including the Trade Practices Act and which by Statute cannot be excluded, restricted or modied. Note: Under the terms of warranty, wear parts such as drive rollers and guide tubes are not covered. Direct or indirect damage due to a defective product is not covered under this warranty.The warranty is void if changes are made to the product without approval from BOC, or if repairs are carried out using nonapproved spare parts.The warranty is void if a non-authorised person carries out repairs. Warranty Period The warranty is valid for the period shown below from the date of purchase to the initial end user and provided the equipment is used within the published specication limits. 5 years 2 years 3 months No Warranty Main transformer, Inductor and Rectier. All other parts including control circuit board. Mig guns. Wear parts and consumables e.g. feed rollers, guide tubes.

13. Glossary
ASEA Australian Standard Equal Angle Burn back Fusing the wire electrode to the contact tip CO2 Carbon dioxide Contact tip A short tube tted to a MIG gun to pass electrical current onto the wire Current density The current for a given ller wire diameter Deposition rate The weight of metal deposited in a unit of time, expressed as kg/hr Duty cycle Percentage of time, for a test period during which power supply can be operated at its rated output without overloading Dwell time The period of time the nozzle remains on the job after welding to protect the cooling weld Flow meter A gas ow measuring device connected to the regulator to adjust operating ow rates Globular transfer Metal transfer which takes places as globules of a diameter larger than that of the electrode GMAW Gas metal arc welding Inert gas Shielding gas consisting of argon or helium or a mixture of the two Liner Supply conduit that the wire electrode feeds through Rectier A power source developed to supply direct current (DC) for welding from an alternating (AC) mains power supply Short arc transfer Metal transfer in which fused particles of wire electrode are detached in rapid succession during the repeated short circuiting contacts the weld pool Spatter The metal particles which are expelled during welding on to the surface of the parent metal or a weld and which do not form a part of the weld Spray transfer Metal transfer which takes place as a rapidly projected stream of droplets of a diameter no larger than that of the wire electrode Stickout The length the wire electrode projecting past the contact tip during the welding Variables Operating conditions such as volts, wire speed, travel speed and gas ow rate that are adjustable before and during welding Weld time Total time involved between the start and nish of welding current during the make of one weld

Undertaking Warranty Repairs BOC or their authorised service provider must be informed of warranty defects within the warranty period. Before any warranty work is undertaken, the initial end user must provide proof of purchase and serial number of the equipment in order to validate the warranty. Any parts replaced under the terms of the warranty remain the property of BOC.

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