BossWeld MST185, Manual

Page 1: ...INVERTER MIG TIG STICK WELDER MANUAL MST185 2 YEAR LIMITED WARRANTY 10AMP PLUG ...

Page 2: ...ffort 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 oxidisation in the weld Weld with or without gas Point and pull the trigger Great for maintenance small projects automo...

Page 3: ... REPLACEMENT 15 DRIVE ROLLER SIZE 16 2T 4T TRIGGER CONTROL INFORMATION 16 LIFT ARC START 17 MIG TORCH AND CONSUMABLE CARE 18 STICK MMA WELDING SETUP 19 20 GENERAL MMA WELDING 21 GASLESS MIG WELDING SETUP 22 24 GAS MIG WELDING SETUP 24 27 GENERAL MIG WELDING 28 31 TIG WELDING SETUP 32 33 TUNGSTEN PREPARATION 34 GENERAL TIG WELDING 35 BZ15 MIG TORCH PARTS BREAK DOWN 36 17 SERIES TIG TORCH BREAKDOWN ...

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: ...lder 2 3 metre 15 Series MIG Torch 3 Electrode Holder Lead 4 Welding Earth Lead 5 Gas Hose 6 Dual Stage Argon Regulator 7 Torch Spares 8 Drive Roller Installed in Machine 0 8 0 9 V Groove not shown Gasless Drive Roller 0 8 0 9mm Spare Drive Roller not shown 9 Owners Manual not shown 1 2 3 4 5 6 7 ...

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: ...nection Socket 5 Tig Torch Control Socket 6 Gas Output for TIG process REAR PANEL 7 Mains Power Switch 8 Gas Input Note This machine has a Quick connect fitting The Gas hose supplied has hose clamp fitting optional quick connect upgrade available 9 240V AC Mains Power Cord 10 10Amp Input Plug 11 Cooling Fan 6 4 1 2 7 11 5 8 3 9 10 ...

Page 11: ... Voltage Arc Force Down slope Adjustment Set Welding Volts in MIG mode Adjust Arc Force in Stick MMA mode Adjust the current down time in TIG mode 8 Voltage Arc Force and Downslope Display Displays the Welding voltage when machine is in MIG Displays the Arc Force when machine is in Stick MMA Displays the Downslope current down time in TIG 9 Voltage LED Illuminates when Voltage selection is on use ...

Page 12: ...rive Roller E Drive Roller Retainer Nut F Wire Inlet G Wire Guide Inlet Tube H Wire Feed Tensioning Adjustment I Idle Roller Wire Tensioning Arm C C DCEN Polarity Switching Terminal Set for Gasless Welding DCEP Polarity Switching Terminal Set for Gas Welding DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY ...

Page 13: ...eck the Drive roller is matched to the wire size for the job Note Correct wire side on roller to face into machine when fitting Then replace the Drive Roller Cover See Page 16 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 Hub Nut and adjust firmly without too much pressure Note Pictures m...

Page 14: ...chine Trim wire to the end of the nozzle Attach the Euro Connect MIG torch to the machine feeding the wire into the liner Tighten MIG Torch connector to machine Remove nozzle A and tip B from torch A B Re install tip over the wire and tight en using the tool supplied Do NOT over tighten or you may damage the tip holder and re attach nozzle to torch Note Pictures may vary from your machine model 1 ...

Page 15: ...nut up all the way Carefully remove the liner completely from the torch PART NO DESCRIPTION ORIGINAL REF 92 04 B3 Blue steel liner 0 6 0 8mm 3mt 124 0011 92 04 B4 Blue steel liner 0 6 0 8mm 4mt 124 0012 92 04 B5 Blue steel liner 0 6 0 8mm 5mt 124 0015 92 04 R3 Red steel liner 0 9 1 2mm 3mt 124 0026 92 04 R4 Red steel liner 0 9 1 2mm 4mt 124 0031 92 04 R5 Red steel liner 0 9 1 2mm 5mt 124 0035 92 0...

Page 16: ...rmal overload light is illuminated The welder will then cool itself down and once the thermal overload indicator light is no longer illuminated welding can then re commence Please note Exceeding the machine s duty cycle cannot be considered grounds for warranty or return The term duty cycle indicates the percentage welding time available at the output current for each 10 min period over 4 hours Th...

Page 17: ...e 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 Note Pictures may vary from yo...

Page 18: ...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 19: ...are metal 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 clamp connector into the negative terminal Electrode holder connector into the positive terminal DCEN Straight Polarity Earth clamp connector into the Positive terminal Ele...

Page 20: ...ll start You can adjust the Arc force by using voltage Parameter adjustment knob 5 8 6 Select your required current by turning the Welding Parameter Adjustment Knob Please see table on page 21 as a guide to Welding Parameters 7 9 Amperage Selection Guide Rod Size Gauge Welding Current 1 6mm 40 50 Amps 2 0mm 50 75 Amps 2 5mm 75 105 Amps 3 2mm 105 140 Amps 4 0mm 140 160 Amps Average Metal Thickness ...

Page 21: ...g low voltage short arc length conditions while welding Helps avoid sticking stick electrodes when a short arc length is used POWER SOURCE Electrodes can be operated with AC and DC power supplies Not all DC electrodes can be operated on AC power sources however AC electrodes may be used on either AC or DC Base Metal Electrode Type Type Mild Steel Mild Steel General Purpose 6013 Stainless Steel Sta...

Page 22: ...rive roller is matched to the wire size and type Refer to Drive Feed Roller Selection on page 16 Note Wire to roll from under spool into wire feeder Set up the wire feed unit as per section Set up Wire Feed Unit 3 2 Install Euro connect MIG torch over the protruding wire line up the spring connectors and screw the Euro connector nut up firmly 4 Plug the machine 10Amp input power lead into the wall...

Page 23: ...trim wire to the end of the nozzle The multifunction digital display will show two numbers On the left is the wire speed on the right is welding voltage These values are adjusted by rotating the Welding Parameter Adjustment Knobs below them Switch the machine on using the mains power switch Wait a few seconds whilst the machine powers up Remove nozzle and tip from torch and press trigger on the we...

Page 24: ... the Euro Connection terminal NOTE Ensure connector nut is tighten firmly 6 Connect earth Clamp to the terminal 8 Select MIG mode 14 15 Fit gas regulator to bottle and install gas hose to the inlet on the back panel of welder Turn on regulator and set gas flow to between 10 15 L min depending on your welding environment Note This machine has a Quick connect fitting The Gas hose supplied has hose c...

Page 25: ...nstall Euro connect MIG torch over the protruding wire line up the spring connectors and screw the Euro connector nut up firmly 4 Plug the machine 10Amp input power lead into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Drive roller size mm DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY Fit the Earth lead Dinse Plug to the negative terminal for gas welding...

Page 26: ... machine powers up Remove nozzle and tip from torch and press trigger on the welding torch this will feed the wire through the torch Release button when wire appears at the end of the torch Press the Welding Mode Selection Button until the MIG indicator is lit 7 It is recommended for ease of use that the wire feed target speed is adjusted first and then the voltage setting fine tuned if necessary ...

Page 27: ...the back panel of welder Turn on regulator and set gas flow to between 10 15 L min depending on your welding environment 13 Note It is advisable to run a few test welds using scrap or offcut materials in order to tune the machine to the correct settings prior to welding the job Note Pictures may vary from your machine model ...

Page 28: ...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 29: ...tainless Steel Aluminium Mig Wire Gas Shielded Mig Wire Gas Shielded 0 8mm 0 9mm 1 2mm 0 8mm 0 9mm 1 0mm 1 2mm 0 8 1 0 40 50 1 2 50 60 50 70 1 6 65 80 75 95 90 110 2 0 75 90 85 105 90 115 3 0 95 120 125 135 110 130 110 135 120 140 4 0 140 155 145 155 135 150 140 160 145 170 6 0 175 190 150 175 155 180 165 190 8 0 200 210 220 250 185 220 190 230 10 0 220 240 240 265 220 250 12 0 235 250 250 Gas Arg...

Page 30: ...rial being welded and the application The wire is fed from a reel by a motor drive and the welder moves the welding torch along the joint line Wires may be solid simple drawn wires or cored composites formed from a metal sheath with a powdered flux or metal filling Consumables are generally competitively priced compared with those for other processes The process offers high productivity as the wir...

Page 31: ...e normally used for the various materials are Steels CO2 argon 2 to 5 oxygen argon 5 to 25 CO2 Non ferrous e g Aluminium copper or nickel alloys Argon argon helium Argon based gases compared with CO2 are generally more tolerant to parameter settings and generate lower spatter levels with the dip transfer mode However there is a greater risk of lack of fusion defects because these gases are colder ...

Page 32: ...sure the Gas regulator is in the off position Note This machine has a Quick connect fitting The Gas hose supplied has hose clamp fitting optional quick connect upgrade available Set up the TIG torch Place the Tungsten Electrode into the torch head and ensure back cap and collet body are screwed in firmly 3 Plug the machine 10Amp input power plug into the wall socket ensuring that the power switch ...

Page 33: ... between 10 15 L min depending on your welding environment You can also adjust the Down slope by adjusting the knob to the desired setting 9 Fit the Earth lead Dinse Plug to the positive terminal for gasless welding and then connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal 5 Note It is advisable to run a few test welds using scrap or offcut materials...

Page 34: ...orkpiece surface In DC because arc heat is distributed approximately one third at the cathode negative and two thirds at the anode positive the electrode is always negative polarity to prevent overheating and melting However the alternative power source connection of DC electrode positive polarity has the advantage in that when the cathode is on the workpiece the surface is cleaned of oxide contam...

Page 35: ...eignited at each reversal of polarity HF sparks are generated across the electrode workpiece gap to coincide with the beginning of each half cycle APPLICATIONS TIG is applied in all industrial 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 deposit...

Page 36: ...g 92 01 25 06 Contact tip heavy duty 0 6mm x M6 x 8mm dia x 25mm long 92 01 25 08 Contact tip heavy duty 0 8mm x M6 x 8mm dia x 25mm long 92 01 25 09 Contact tip heavy duty 0 9mm x M6 x 8mm dia x 25mm long 92 01 25 10 Contact tip heavy duty 1 0mm x M6 x 8mm dia x 25mm long 92 01 M6A09 Contact tip 0 9mm x M6 Al x 8mm dia x 28mm long 92 01 M6A10 Contact tip 1 0mm x M6 Al x 8mm dia x 28mm long PART N...

Page 37: ...dy 1 0mm 9510N31 Collet Body 1 6mm 9510N32 Collet Body 2 4mm 9510N28 Collet Body 3 2mm 95406488 Collet Body 4 0mm PART NO DESCRIPTION 9510N50 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 95...

Page 38: ...lown away or not available Suitable for seldom use or when bottle hire is not practical or too costly for small jobs and infrequent use Great on galvanised materials Not suitable for panel steel Leaves chalky residue This is normal Producers smoke and splatters It is important that correct drive roller is used to get the best results V groove Roller Roller has a small V shaped groove to guide the ...

Page 39: ...n 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 Check the welding connectors are tight in the sockets Check Leads are not reversed and correct _ Replace w...

Page 40: ... Ring Bring the torch closer to the work and maintain stick out 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 ...

Page 41: ...ing used see machine set up Adjust the wire feed speed Adjust the voltage setting Small diameter wires and soft wires like aluminium don t feed well through long torch leads replace the torch with a lesser length torch Remove the kink reduce the angle or bend Replace the tip with correct size and type Try to clear the liner by blowing out with compressed air as a temporary cure it is recommended t...

Page 42: ...precipitation intergranular corrosion when welding low carbon stainless steel grades higher silicon levels offer improved arc stability bead shape edge wetting 316LSi would be considered the most widely used stainless steel MIG wire CODE DESCRIPTION 200342 Bossweld Gasless GS MIG x 0 8mm x 0 9 Kg 200344 Bossweld Gasless GS MIG x 0 9mm x 0 9 Kg 200343 Bossweld Gasless GS MIG x 0 8mm x 4 5 Kg 200345...

Page 43: ...0 Dissimilar x 3 2mm x 25 Pkt 110190 Stainless Steel 316L 16 x 2 0mm x 25 Pkt 110210 Stainless Steel 316L 16 x 2 6mm x 25 Pkt 110230 Stainless Steel 316L 16 x 3 2mm x 25 Pkt 110240 General Purpose 6013 x 1 6mm x 25 Pkt 110250 General Purpose 6013 x 2 0mm x 25 Pkt 110260 General Purpose 6013 x 2 6mm x 25 Pkt 110270 General Purpose 6013 x 2 6mm x 50 Pkt 110280 General Purpose 6013 x 3 2mm x 25 Pkt 1...

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