BossWeld 200X, Manual

Page 1: ...INVERTER TIG MMA WELDER MANUAL Inverter Multiprocess Welde ...

Page 2: ...or maintenance small projects automotive repairs METAL TYPES Mild steel stainless steel aluminium S STICK Easiest process to learn Best choice for quick repairs Slower than MIG welding Forgiving in dirty rusty environments Not recommended for thin sheet metal welding METAL TYPES Mild steel stainless steel cast iron T TIG Gives a better weld finish Accurate heat control Considered the most challeng...

Page 3: ... CYCLE 13 GENERAL AC DC WELDING 14 GENERAL PULSE WELDING 15 GENERAL 2T 4T TRIGGER CONTROL 16 GENERAL LIFT ARC HF START 16 17 FOOT CONTROL UPGRADE OPTIONS 17 STICK MMA WELDING SETUP 18 19 ELECTRODE CURRENT SELECTION 20 GENERAL MMA WELDING 21 TIG WELDING SETUP 22 23 AC DC WELD CYCLE SETUP 24 26 TUNGSTEN PREPERATION TIG WELDING 27 TIG WELDING CONTINUED 28 26 TIG TORCH BREAKDOWN 29 TROUBLE SHOOTING 30...

Page 4: ...non standard parts 9 Repair case opening tampering with modifications to any part of the item by non authorised BOSSWELD repairers This warranty covers the machine only and does not include Torches Leads Earth Clamps Electrode holders Plasma Torches Tig Torches and any of the parts on those items unless there is a manufacturing fault 1 REGISTRATION Purchasers are encouraged to register for warrant...

Page 5: ...er Box Contents 1 AC DC 200X Inverter TIG MMA Welder 2 4m 26 Series TIG Torch 3 Electrode Holder Lead 4 Welding Earth Lead 5 Gas Hose 6 Carry Strap 7 Dual Stage Argon Regulator 8 Torch Spares not shown 9 Owners Manual not shown 1 2 3 4 5 7 6 ...

Page 6: ... necessary or non reflecting welding curtain Do not let children or animals have access to the welding equipment or to the work area SWITCHING OFF When the operator has finished welding they must switch the welder off DO NOT put the electrode holder down with the welder switched ON When leaving the welder unattended move the ON OFF switch to the OFF position and disconnect the welder from the elec...

Page 7: ...G The user of this welder is responsible for their own safety and the safety of others It is important to read understand and respect the contents of this user guide When using this welder basic safety precautions including those in the following sections must be followed to reduce the risk of fire electric shock and personal injury Ensure that you have read and understood all of these instruction...

Page 8: ...e used in conjunction with a residual current device RCD with rated residual current of 30MA or less In general the use of extension leads should be avoided If used however ensure that the extension lead is used with the welder is of a suitable current rating and heavy duty in nature that MUST have an earth connection If using the welder outdoors ensure that the extension lead is suitable for outd...

Page 9: ...st Check with your local council authority for recycling advice MAINTENANCE DISPOSAL GAS BOTTLE ATTENTION CHECK FOR GAS LEAKS At initial set up and at regular intervals we recommend to check for gas leakage Recommended procedure is as follows 1 Connect the regulator and gas hose assembly and tighten all connectors and clamps 2 Slowly open the cylinder valve 3 Set the flow rate on the regulator to ...

Page 10: ...Output Connection 6 Remote Controller Plug 7 Gas Output Connector 8 AC DC Selection Switch 9 Welding Mode Selection Button 10 2T 4T Selection Switch REAR PANEL 11 240V AC Mains Power Switch 12 Gas Inlet Connector 13 Cooling Fan 14 15 Amp Input Plug 3 4 10 9 8 2 1 5 13 6 11 7 12 14 DO NOT GRIND YOUR PLUG This will void any warranty on your machine ...

Page 11: ... Seconds Hertz Amps Volts and scroll through weld cycle Turn to adjust selected parameter the selected parameter will be illuminated 19 LCD Display panel 20 Illuminates when Seconds is displayed on LCD panel 21 Illuminates when Percentage is displayed on LCD panel 22 Illuminates when Hertz is displayed on LCD panel 23 Illuminates when Amps is displayed on LCD panel 24 Illuminates when Volts is dis...

Page 12: ...rrent Amps DC 10 170 AC 10 200 3 Upslope Time Seconds 1 0 10 0 4 Welding Peak Current Amps TIG DC 10 170 TIG AC 10 200 MMA DC 10 200 MMA AC 10 200 5 No Pulse Weld On or off 6 Pulse Weld On or off 7 Welding Base Current Amps TIG DC 10 170 TIG AC 10 200 MMA DC 10 200 MMA AC 10 200 8 Ratio of pulse Duration to Base Current Duration 5 95 9 Pulse Frequency Hz 0 5 200 10 Downslope Time Seconds 0 10 11 B...

Page 13: ...urrent for each 10 min period over 4 hours The specification plate on the machine list three given ratings at a given current and voltage NOTE Amps refer to the Current setting TIG DC setting duty cycle shown 25 60 100 170 Amps 125 Amps 100 Amps 16 8 Volts 15 6 Volts 14 4 Volts For example this means when the machine is set at a current of 170 Amps in TIG AC it can only weld for Two an a half minu...

Page 14: ...in shipbuilding because the current settings can often be higher than those used in DC welding and a deeper penetration of plate metals can be obtained The biggest drawback to using AC welding is the quality of the weld It is not as smooth as DC welding because of the continuous change in directional flow and there is likely to be more spatter Applications of DC Welding Welding with DC is best use...

Page 15: ...especially thin By pulsing along the weld joint you can moderate the amount of filler metal you add so that it s evenly distributed and you create a great looking weld Minimal Movement If you re in a tight spot and you don t have a lot of room to maneuver pulsing your TIG welder is one way to glide along the weld joint adding filler metal as you go without worrying about introducing too much heat ...

Page 16: ... amperage selected on the amperage dial 4 When you want to finish the weld press and hold the trigger and the amperage will begin to downslope at the rate you have selected on the downslope dial amperage will remain at this level until you release the trigger 5 Once you have released the trigger the arc will stop and the postflow gas will continue for a pre set amount of time LIFT ARC START With a...

Page 17: ...Amps the foot controller range will be between min and 120 Amps Bossweld Foot Control 3mt Part No 660201 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece 1 Press the button on the TIG torch 2 The Arc will start forming an arc between the tungsten tip and the work piece 3 Note Pictures may vary from your machine model ...

Page 18: ...makes good contact with bare metal Take electrode holder and twist the handle to open the lock Insert bare metal rod end of electrode and twist the handle to clamp electrode 3 4 Assemble Arc and Earth leads into the welding terminals depending on requirements of electrodes Refer to your electrode packet for polarity and current requirements DCEP Negative Polarity most common application Earth clam...

Page 19: ... form AC or DC using the AC DC Selection switch DC is the most common electrode type MACHINE SET UP STICK MMA CONTINUED 5 6 7 Select your required amperage by turning the Multi Function Control knob You can adjust the Hot Start by pressing the Multi Function Control knob to cycle to Hot start then adjusting to the required parameter You can adjust the Arc force by pressing the Multi Function Contr...

Page 20: ... an electrode will require about 40 Amps per millimetre diameter Therefore the preferred current level for a 4mm diameter electrode would be 160 Amps but the acceptable operating range is 140 to 180 Amps It is important to match the machine to the job Average Metal Thickness Electrode Size 1 0 2 0mm 2 0mm 2 0 5 0mm 2 6mm 5 0 8mm 3 2mm 8 0mm 4 0mm ELECTRODE SIZE SELECTION Electrode size selection w...

Page 21: ... example if welding Mild Steel then select a Mild Steel General Purpose Electrode Electrodes are identified by a universal numbering system AWS Type code Electrodes are often packed in sealed packaging to keep moisture out However if a pack has been opened or damaged it is essential that the electrodes are redried according to the manufacturer s instructions ARC FORCE Also called Dig and Arc Contr...

Page 22: ... torch Place the Tungsten Electrode into the torch head and ensure back cap and collet body are screwed in firmly 3 Plug the machine 15Amp input power plug into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Connect the Argon Gas Regulator supplied to the Gas bottle and connect the Gas Hose to the Gas Input socket on the rear of machine and the Regulator Ens...

Page 23: ...ng the job Select AC or DC welding AC DC Selection Switch Fit the Earth lead Dinse Plug to the positive terminal and then connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal Set remaining parameters referring to the table on page 24 to 26 Please note not all parameters are relevant to DC TIG welding Switch the machine on using the mains power switch Wai...

Page 24: ...lse Selection for Pulse or No Pulse Base Current only when Pulse is Selected Selection for the Base Welding Amperage required during welding DownSlope Selection for the transition time from Peak Amperage to Finish Amperage Crater Arc Current Selection for the amount of fill at the end of the weld Post Gas Selection for gas flow time after the arc finishes AC WELDING ONLY Balance Selection to adjus...

Page 25: ...ired parameter Amps DC 10 170 AC 10 200 Pressing the Multi Function Control knob to cycle to Pulse Function you can either select No Pulse or Pulse the digital screen will display like below NO PULSE PULSE Pressing the Multi Function Control knob to cycle to Upslope then adjusting to the required parameter 1 0 10 0 Seconds NOTE STEPS 6 to 8 ONLY VALID IF PULSE IS SELECTED Pressing the Multi Functi...

Page 26: ...ol knob to cycle to Post gas then adjusting to the required parameter 1 0 10 0 Seconds Pressing the Multi Function Control knob to cycle to Frequency then adjusting to the required parameter Hz 0 5 200 NOTE THIS STEP IS ONLY VALID IN AC WELDING Pressing the Multi Function Control knob to cycle to Balance then adjusting to the required parameter 5 5 Pressing the Multi Function Control knob to cycle...

Page 27: ...nation For this reason AC is used when welding materials with a tenacious surface oxide film such as aluminium ARC STARTING The welding arc can be started by scratching the surface forming a short circuit It is only when the short circuit is broken that the main welding current will flow However there is a risk that the electrode may stick to the surface and cause a tungsten inclusion in the weld ...

Page 28: ...rial sectors but is especially suitable for high quality welding In manual welding the relatively small arc is ideal for thin sheet material or controlled penetration in the root run of pipe welds Because deposition rate can be quite low using a separate filler rod MMA or MIG may be preferable for thicker material and for fill passes in thick wall pipe welds TIG is also widely applied in mechanise...

Page 29: ... Alumin Cup Size 4 9510N49 Alumin Cup Size 5 9510N48 Alumin Cup Size 6 9510N47 Alumin Cup Size 7 9510N46 Alumin Cup Size 8 9510N45 Alumin Cup Size 10 9510N44 Alumin Cup Size 12 PART NO DESCRIPTION 9545V24 Gas Lens Collet 1 0mm 9545V25 Gas Lens Collet 1 6mm 9545V26 Gas Lens Collet 2 4mm 9545V27 Gas Lens Collet 3 2mm 9545V28 Gas Lens Collet 4 0mm PART NO DESCRIPTION 9554N18 Gas Len Alumin Cup Size 4...

Page 30: ... into the 240V mains outlet and is switched on Check that the mains fuse or breaker has not operated Check that the main switch on the rear of the unit is in the on position Check output connectors are connected properly and are not damaged Check connections and that workpiece is free of paint and rust at connection point Allow the unit to cool for 20 minutes Check earth clamp is connected to work...

Page 31: ...tarily hold arc on side walls if using weaving technique Select a lower voltage range Material too thick Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics Keep the arc at the leading edge of the weld pool and maintain the gun angle at 5 15 keeping the stick out between 5 10mm Select a higher voltage range ...

Page 32: ...OTHER PRODUCTS IN OUR RANGE ELECTRODES TIG RODS WELDING HELMETS WELDING MACHINES TORCH SPARE PARTS WELDING ACCESSORIES MIG WIRE GAS EQUIPMENT WELDING SAFETY MIG TORCHES TIG TORCHES WELDING CABLE ...