BossWeld M100, Manual

Page 1: ...INVERTER GASLESS MIG WELDER MANUAL M100 1 YEAR LIMITED WARRANTY ...

Page 2: ...actured to the highest standards so that performance is maximised We truly hope you enjoy using your welder Every effort has been made to ensure that this manual has been prepared accurately however errors and omissions are excepted BOSSWELD is a trademark of Dynaweld Industrial Supplies Pty Ltd M MIG Simple to learn MIG Wire is fed through the gun to create the weld pool Gas or flux prevents oxid...

Page 3: ...SAL 9 FRONT REAR PANEL LAYOUT 10 MACHINE INSIDE 11 MACHINE SET UP 12 13 DUTY CYCLE DRIVE ROLLER SIZE 14 MIG TORCH AND CONSUMABLE CARE 15 BASIC MIG WELDING GUIDE 16 17 COMMON WEAR PART 18 BZ15 MIG TORCH PARTS BREAK DOWN DRIVE ROLLERS BZ15 MIG TORCH REPLACEMENT WELDING CONSUMABLES 19 HELPFUL INFORMATION TROUBLE SHOOTING 20 23 ...

Page 4: ...ing 5 Environmental factors such as usage in temperatures exceeding 40 degrees above 1000mt sea level rain water excessive damp cold or humid conditions 6 Improper setup or installation 7 Use on Incorrect voltage or non authorised electrical connections and plugs 8 Use of non standard parts 9 Repair case opening tampering with modifications to any part of the item by non authorised BOSSWELD repair...

Page 5: ...1 BOSSWELD M100 Inverter Gasless MIG Welder 2 Direct Connect MIG Torch 2 5M 3 Direct Connect welding Earth cable with Earth Clamp 4 Carry Strap 5 Cable Lead tidy 6 Torch Spares 7 Gasless 0 6 0 8mm Driver Roller Installed 8 Owners Manual not shown 1 2 3 4 5 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: ...TRANSPORT Store the welder and accessories out of children s reach in a dry place If possible store the welder in the original packaging The appliance must unconditionally be secured against falling or rolling over during transport DISPOSING OF THE PACKAGING Recycling packaging reduces the need for landfill and raw materials Reuse of the recycled material decreases pollution in the environment Ple...

Page 10: ...Overload Error Indicator Light 3 Welding Voltage Control Knob 4 Wire Speed Control Knob 5 Welding Earth Lead 6 MIG Torch Output REAR PANEL 7 Cooling Fan 8 Mains Power Switch 9 240V AC Mains Power Cord 10 10 Amp Input Plug 2 3 1 5 8 10 9 4 6 7 ...

Page 11: ...ol Hub NOTE This unit is suitable for D100 Rolls of Gasless MIG Wire 1Kg in weight B Spool Hub Nut C Wire Drive Assembly D Drive Roller E Drive Roller Cover F Idle Roller G Guide Tube H Wire Feed Tensioning Knob I Wire Tensioning Arm J Inlet Tube C ...

Page 12: ...l Hub Remove the Drive Roller Cover Check the Drive roller is matched to the wire size for the job Note Correct wire side on roller to face out off machine when fitting Then replace the Drive Roller Cover before feeding the wire See Page 14 for drive roller size and type Put down Wire Tensioning Arm so it locks into position and turn the Wire Feed Tensioning Knob to gently tighten Replace Spool Hu...

Page 13: ... of the machine for suggested machines settings and material thickness Set The welding Voltage and Wire Speed according to chart Remove nozzle A and tip B from torch A B Re install tip over the wire and tighten Do NOT over tighten or you may damage the tip holder and re attach nozzle to torch NOTE Make sure your torch is layed out straight Note Pictures may vary from your machine model 9 11 13 14 ...

Page 14: ...o Minutes in a Ten minute period The power source is protected by a built in temperature protection device This will activate if the machine is operated in excess of its amperage and duty cycle rating Duty Cycle Amperage Current Voltage Approx 15 Amps Approx 50 Amps Approx 100 Amps Diagram Below shows approx amperage on welding voltage dial This light indicates Over temperature Duty cycle exceeded...

Page 15: ...ent However performing some simple maintenance can help extend consumable life and improve gun performance and weld quality The gas diffuser provides gas flow to the weld pool and also connects to the neck and carries the electrical current to the contact tip Make sure all connections are tight and check the diffuser s O rings for cracks cuts or damage The nozzle s main role is to focus the shield...

Page 16: ...at wire speed is constant if the welding voltage is too high large drops will form on the end of the electrode wire causing spatter if the voltage is too low the wire will not melt POSITION OF MIG GUN The angle of MIG gun to the weld has an effect on the width of the weld run Distance from the MIG Gun Nozzle to the Work Piece The electrode stick out from the MIG gun nozzle should be between 2 0mm ...

Page 17: ...e process offers high productivity as the wire is continuously fed Manual MIG welding is often referred as a semi automatic process as the wire feed rate and arc length are controlled by the power source but the travel speed and wire position are under manual control The process can also be mechanised when all the process parameters are not directly controlled by a welder but might still require m...

Page 18: ...justable conical nozzle ø 12mm 92 02 15 CL Adjustable cylindrical nozzle ø 19mm 92 02 15 10 Adjustable tapered nozzle ø 10mm M6 Standard Duty M6 Heavy Duty CL CO 10 MACHINE DRIVE ROLLER SIZE NOTE MACHINE WILL RUN UP TO 0 8MM WIRE Knurled Drive Roller For Gasless Wire 25mm 7mm 7mm A TTENTIO N Recommend using Gasless 0 8mm x 0 9kg THIS MACHINE ONLY WORKS WITH GASLESS MIG WIRE 0 9 K g S p ools ONLY P...

Page 19: ...d E size gas cylinders and comes with 2 safety chains Large 7 5cm casters for easy movement Welders sits at an angle for easy access to controls Handy cable hangers Overall dimension 70 5cm L x 41 9cm W x 77 5cm H Bossweld Spring Handle Chipping Hammer Used for slag removal and cleaning up weld beads post weld Spring handle for increased comfort Features Robust Spring Handle Hardened point and chi...

Page 20: ...ne prevent the flux from burning and make removal slag easier To stop welding break the circuit withdraw the tip from the work piece Be careful with the end of the MIG Torch as it will be HOT Provided the current setting is correct the surface of the work piece will also melt by the intensity of the arc A degree of penetration is thereby obtained and a complete fusion of the work piece and the dep...

Page 21: ...e 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 piece properly Change the Main Supply to an alternative Che...

Page 22: ...ut of 5 10mm Increase the voltage Decrease the wire feed speed Remove materials like paint grease oil and dirt including mill scale from base metal Select a higher voltage range and or adjust the wire speed to suit Keep the arc at the leading edge of the weld pool Gun angle to work should be between 5 15 Direct the arc at the weld joint Adjust work angle or widen groove to access bottom during wel...

Page 23: ...uires 0 8mm drive roller Fit the correct type roller e g knurled rollers needed for flux cored wires Replace the drive rollers Reduce the spool hub brake tension Remove the spool untangle the wire or replace the wire Use clean dry rust free wire Do not lubricate the wire with oil grease etc MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MI...

Page 24: ... 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 Version 1 0 2019 ...