BossWeld MST195, Manual

Page 1: ...INVERTER MIG TIG STICK WELDER MANUAL MST195 2 YEAR LIMITED WARRANTY ...

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: ...INSTALATION REPLACEMENT 15 DRIVE ROLLER SIZE 16 2T 4T TRIGGER CONTROL INFORMATION 16 BURNBACK CONTROL 16 LIFT ARC START 17 MIG TORCH AND CONSUMABLE CARE 18 SITCK 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 PREPERATION 34 GENERAL TIG WELDING 35 BZ15 MIG TORCH PARTS BREAK DOWN 36...

Page 4: ...ns 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 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 t...

Page 5: ...tre 15 Series MIG Torch 3 Electrode Holder Lead 4 Welding Earth Lead 5 Gas Hose 6 Dual Stage Argon Regulator 7 Cable Lead Tidy 8 Torch Spares 9 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 10 Owners Manual not shown 1 2 3 4 5 6 7 8 ...

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: ...n Socket 3 Positive Output Connection Socket 4 Negative Output Connection Socket 5 Tig Torch Control Socket 6 Gas Output for TIG process REAR PANEL 7 Mains Power Switch 8 Gas Input 9 240V AC Mains Power Cord 10 15Amp 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: ...Terminal E Drive Roller F Drive Roller Retainer Nut G Wire Inlet H Wire Guide Inlet Tube I Wire Feed Tensioning Adjustment J Idle Roller Wire Tensioning Arm D D 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: ...achine Trim wire to the end of the nozzle Attach the Euro Connect MIG torch to the machine fedding 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 tighten 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 Carfully 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 04...

Page 16: ...et amount of time BURNBACK CONTROL Burnback control sets the amount of wire to burn back after you release the trigger of your torch this setting which adjust the amount of time that the welding wire remains electrically energized after the wire feeding has stopped Setting your Burnback Control to the wrong setting can cause the wire to stick to your work PART No DESCRIPTION Knurled Drive Roller F...

Page 17: ...ce with the Tungsten Electrode 1 2mm from the work piece With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece Press the button on the TIG torch Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 1 3 2 4 ...

Page 18: ...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 shielding gas around the weld...

Page 19: ...akes good contact with bare 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 t...

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: ... machine ensuring the drive 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 15Amp input p...

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: ...e correct settings prior to welding the job 4 Connect Mig Torch to 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 IMPORTANT We...

Page 25: ...t 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 15Amp 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...

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: ...ose to the gas 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 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 ...

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: ... Gas Hose to the Gas Input socket on the rear of machine and the Regulator Ensure the Gas regulator is in the off position 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 15Amp input power plug into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Connect the Arg...

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: ...TION 92 ER 15 3 BZ Style 15 MIG Torch 3m 92 ER 15 4 BZ Style 15 MIG Torch 4m 92 ER 15 5 BZ Style 15 MIG Torch 5m GAS HOLDER GAS NOZZLE SWAN NECK SPRING CONTACT TIP INSULATOR Euro Connector BZ15 BOSSWELD BINZEL STYLE MIG TORCH COMPLETE ...

Page 37: ...itch Dinse 50 95 26 8 1 SW DA50 Tig Torch 26 8mt 1 pc Switch Dinse 50 BOSSWELD 26 SERIES 200AMP TIG TORCH COMPLETE BACK CAP INSULATOR COLLET COLLET BODY COMPACT GAS LENS ALUMINA CUP ALUMINA CUP TORCH BODY COMPACT GAS LENS COLLET BODY COMPACT INSULATOR FLEX TORCH BODY ...

Page 38: ...le for outside use where gas shield can be blown 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 Producres smoke and splatters It is important that correct drive roller is used to get the best results V groove Roller Roll...

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...

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Page 44: ...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 ...