MODEL
•
•
BOSS Inverter MIG 165
BOSS Inverter MIG 200
Operating Manual
(Owner’
s Manual)
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
First Edition
September, 2008
Manual No. B0804
CONTENTS
SYMBOL LEGEND---------------------------------------------------------------------------------------------------2
STATEMENT OF WARRANTY------------------------------------------------------------------------------------3
1.0
GENERAL INFORMATION-------------------------------------------------------------------------------4
1.01 Notes, Cautions and Warnings------------------------------------------------------------------------4
1.02 Important Safety Precautions--------------------------------------------------------------------------4
1.03 Transporting methods-----------------------------------------------------------------------------------6
2.0
INSTALLATION RECOMMENDATION----------------------------------------------------------------7
2.01 Electrical Input Connections---------------------------------------------------------------------------8
2.02 Installation of MIG/MAG--------------------------------------------------------------------------------9
2.03 Specifications--------------------------------------------------------------------------------------------10
2.04 Duty Cycle------------------------------------------------------------------------------------------------10
3.0
OPERATOR CONTROLS-------------------------------------------------------------------------------11
3.01 INVERTER MIG Series Controls--------------------------------------------------------------------11
3.02 INVERTER MIG Series Control Methods---------------------------------------------------------13
3.03 Weld Parameter Description-------------------------------------------------------------------------13
4.0
SET-UP FOR MIG/MAG---------------------------------------------------------------------------------14
5.0
POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------15
5.01 Basic MIG Welding Guide----------------------------------------------------------------------------16
5.02 Position of MIG GUN-----------------------------------------------------------------------------------16
5.03 Distance from the MIG Gun Nozzle to the Work Piece----------------------------------------16
5.04 Travel Speed---------------------------------------------------------------------------------------------16
5.05 Electrode Wire Size Selection-----------------------------------------------------------------------16
5.06 Spot Welding Operation-------------------------------------------------------------------------------17
6.0
MAINTENANCE--------------------------------------------------------------------------------------------18
7.0
BASIC TROUBLESHOOTING-------------------------------------------------------------------------18
7.01 Check the item and excrescent phenomenon exclusion method-----------------------------18
7.02 Solving Problems Beyond the Welding Terminals -----------------------------------------------20
7.03 Weld Problems--------------------------------------------------------------------------------------------22
7.04 Power Supply Problems--------------------------------------------------------------------------------23
8.0
PART LIST---------------------------------------------------------------------------------------------------24
9.0
REMARK-----------------------------------------------------------------------------------------------------28
-1BOSS Inverter Mig 165、200 Operating Manual
SYMBOL LEGEND
A
V
Hz
Amperage
Stick (SMAW)
Voltage
Pulse Current Function
(GTAW)
Hertz (frequency)
Spot Time (GTAW)
t
SEC
Seconds
Remote outputs control
(Panel/Remote)
%
Percent
Remote Function
DC (Direct Current)
Arc Control (SMAW)
AC (Alternating Current)
Gas Post-Flow Time
t2
2T (GTAW)
Gas Pre-Flow Time
t1
VRD
4T (GTAW)
—
Repeat Function (GTAW)
+
Spot Function (GTAW)
Voltage Reduction
Device Circuit
Negative
Positive
High Frequency Starting
(GTAW)
Gas Input
Lift Start (GTAW)
Gas Output
-2BOSS Inverter Mig 165、200 Operating Manual
STATEMENT OF WARRANTY
LIMITED WARRANTY: "BOSS" warrants to customers of its authorized distributors hereafter "BOSS" that its products will be
free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period
applicable to the BOSS products as stated below, BOSS shall, upon notification thereof and substantiation that the product has
been stored, installed, operated, and maintained in accordance with BOSS’
s specifications, instructions, recommendations and
recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by
suitable repair or replacement, at BOSS ‘s sole option, of any components or parts of the product determined by BOSS to be
defective.
The BOSS COMPANY MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: BOSS shall not under any circumstances be liable for special, indirect or consequential damages,
such as, but not limited to, lost profits and business interruption. The remedies of the Purchaser set forth herein are exclusive
and the liability of BOSS with respect to any contract, or anything done in connection therewith such as the performance or
breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by BOSS whether
arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein,
exceed the price of the goods upon which such liability is based. No employee, agent, or representative of BOSS is authorized
to change this warranty in any way or grant any other warranty.
PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED
WHICH IN BOSS’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY BOSS PRODUCT.
PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to
the Purchaser. Not with standing the foregoing, in no event shall the warranty period extend more than the time stated plus one
year from the date BOSS delivered the product to the authorized distributor.
POWER SUPPLIES
POWER SUPPLIES & WIRE FEEDERS
MAIN POWER MAGNETICS (STATIC& ROTATING)
1YEAR
ORIGINAL MAIN POWER RECTIFIER
1YEAR
POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD
1YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING
1YEAR
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOIDS, PUMPS, SWITCHES, MOTORS
Warranty repairs or replacement claims under this limited warranty must be submitted to BOSS by an authorized BOSS repair
facility within thirty (30) days of purchaser’
s notice of any Warranty Claim. No transportation costs of any kind will be paid under
this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the
Purchas er. All returned goods shall be at the Purchaser’
s risk and expense. This warranty supersedes all previous BOSS
warranties.
-3BOSS Inverter Mig 165、200 Operating Manual
1.0
GENERAL INFORMATION
1.01
Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These
highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in
efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
1.02
Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment. Call your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the Arc welding or cutting process can be dangerous and hazardous to
your health.
l Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
l Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
l The kinds of fumes and gases from the arc welding/cutting depend on the kind of metal being used,
coatings on the metal, and the different processes. You must be very careful when cutting or welding
any metals which may contain one or more of the following:
Antimony
Arsenic
Barium
Beryllium Cadmium Chromium Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium Silver
Vanadium
l Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you
are using. These MSDSs will give you the information regarding the kind and amount of fumes and
gases that may be dangerous to your health.
l Use special equipment, such as water or down draft welding/cutting tables, to capture fumes and
gases.
l Do not use the welding torch in an area where combustible or explosive gases or materials are
located.
l Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove
all sources of these vapors.
-4BOSS Inverter Mig 165、200 Operating Manual
ELECTRIC SHOCK
Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy.
This electric energy can cause severe or fatal shock to the operator or others in the workplace.
l Never touch any parts that are electrically “live”or “hot.”
l Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding
circuit.
l Repair or replace all worn or damaged parts.
l Extra care must be taken when the workplace is moist or damp.
l Install and maintain equipment according to NEC code, refer to relative standards
l Disconnect power source before performing any service or repairs.
l Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the arc weld.
l Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
l Ventilate all flammable or explosive vapors from the workplace.
l Do not cut or weld on containers that may have held combustibles.
l Provide a fire watch when working in an area where fire hazards may exist.
l Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut
underwater, or while using a water table. Do not cut aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Arc welding/cutting processes can cause noise levels to exceed
safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
l To protect your hearing from loud noise, wear protective ear plugs and/ or ear muffs. Protect others
in the workplace.
l Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
ARC WELDING RAYS
Arc Welding/ Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces
very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are
not properly protected.
l To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
l Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
l Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
l Protect others in the work area from the arc rays. Use protective booths, screens or shields.
-5BOSS Inverter Mig 165、200 Operating Manual
1.03
Transporting methods
These units are equipped with a handle for carrying purposes.
WARNING: ELECTRIC SHOCK can kill.
DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply
line before moving the welding power source.
WARNING: FALLING EQUIPMENT can cause serious personal injury and
equipment damage.
l
l
l
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
-6BOSS Inverter Mig 165、200 Operating Manual
2.0
INSTALLATION RECOMMENDATION
Installation Environment
INVERTER MIG Series is designed for use in hazardous environments.
Examples of environments with increased hazardous environments are In locations in which freedom of movement is restricted, so that the operator is forced to perform the work
in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts; In locations which
are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or
accidental contact by the operator, or in wet or damp hot locations where humidity or perspiration
considerable reduces the skin resistance of the human body and the insulation properties of accessories.
Environments with hazardous environments do not include places where electrically conductive parts in
the near vicinity of the operator, which can cause increased hazard, have been insulated.
Installation Location
l
l
l
l
Be sure to locate the welder according to the following guidelines:
In areas, free from moisture and dust.
l In areas, not subjected to abnormal vibration or
In areas, free from oil, steam and corrosive
shock.
gases.
l Place at a distance of 304.79mm or more from
In areas, not exposed to direct sunlight or rain.
walls or similar that could restrict natural airflow
Ambient temperature: between -10 degrees C
for cooling.
to 40 degrees C.
WARNING 1
BOSS advises that this equipment be electrically connected by a qualified electrician.
The following Primary Current recommendations are required to obtain the maximum welding current and
duty cycle from this Power Supply:
Primary
supply lead
size
Minimum primary current
circuit size
Current & Duty Cycle
Inverter Mig 165
Minimum 5mm2
220V/ 26.3A
240V/ 24.1A
160A/22V@60%
140A/21V@100%
Inverter Mig 200
Minimum 6mm2
220V/ 37A
240V/ 33.9A
200A/24V@60%
180A/23V@100%
Model
Table 1
Primary current circuit sizes to achieve maximum current
-7BOSS Inverter Mig 165、200 Operating Manual
2.01
Electrical Input Connections
WARNING: ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is
present after removal of input power.
DO NOT TOUCH live electrical parts
SHUT DOWN welding power source, disconnect input power employing lockout/ tagging procedures.
Lockout/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single phase 50/ 60 Hz, AC power supply. The input voltage must
match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the
local electric utility for information about the type of electrical service available, how proper connections
should be made, and inspection required.
The line disconnect switch provides a safe and convenient means to completely remove all electrical power
from the welding power supply whenever necessary to inspect or service the unit.
According to Table 1 and below as a guide to select line fuses for the disconnect switch.
Input Voltage
Fuse Size
220/240V AC
60 Amps
Model
Inverter Mig 165, 200
Table 2
Notice: Fuse size is based on not more than 200 percent of the rated input amperage of the
welding power source (Based on Article 630, National Electrical Code).
Figure 1 Electrical input connections
-8BOSS Inverter Mig 165、200 Operating Manual
2.02
Installation of MIG/MAG
l Connect the work lead to negative (-) socket (positive (+) for special wire).
l Connect the gun lead to the positive (+) socket (negative (-) for special wire).
l Position a gas cylinder on the rear tray and lock securely to the power supply cylinder bracket with the
chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a
building pillar, wall bracket or otherwise securely fixed in an upright position.
l Fit the gas regulator/ flowmeter to the gas cylinder (choose different gas according to wire: CO2,
mixed gas, argon and so on).
l One dual groove feed rollers are supplied as standard with the power supply. These can
accommodate 0.8mm and 1.0mm diameter hard wires. Select the roller required with the chosen wire
size marking facing outwards.
l Fit the electrode wire spool to the wire reel hub.
l Lift up the wire feeder pressure lever and lift the electrode wire to the entrance of the gun.
l Lower the pressure lever and with the gun lead reasonably straight, feed the wire through the gun, till
to extend from the hole in the middle of contact tip.
l Regulate the current, voltage to the value required according to the thickness of work piece (short
circuit transition, dip transition, and spray transition can be produced according to different regulated
current , voltage).
l Install appropriately, there is no faulty after inspecting, you can start welding.
Wire Size
WF 82E
Idle Roll
Drive
Roll
×1
×1
2WZKIDLE001
0.6/0.8mm
2WZKVY0R6X0R8
2WZKKVY0R6X0R8
2WZKUL0R6X0R8
0.8/1.0mm
2WZKVY0R8X1R0
2WZKKVY0R8X1R0
2WZKUL0R8X1R0
0.9/1.2mm
2WZKVY0R9X1R2
2WZKKVY0R9X1R2
2WZKUL0R9X1R2
1.0/1.2mm
2WZKVY1R0X1R2
2WZKKVY1R0X1R2
2WZKUL1R0X1R2
2WZKKVY1R2X1R2
1.2/1.2mm
Table 3
-9BOSS Inverter Mig 165、200 Operating Manual
2.03
Specifications
MODEL
Inverter Mig 165
Inverter Mig 200
Input voltage and frequency and phases
220/240V 1ph
220/240V 1ph
KVA @ max output
5.8KVA
8.1KVA
Max current
160A
200A
Output current range
30~160A
30~200A
Open circuit voltage
62/68V
62/68V
Duty cycle at 40℃
60%
60%
Weight
30Kg
31Kg
Dimensions
450×210×470
450×210×470
Table 4
2.04
Duty Cycle
The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be
operated at a given output without causing overheating and damage to the unit. If the welding amperes
decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty
cycle will decrease.
WARNING: Exceeding the duty cycle ratings will cause the thermal overload
protection circuit to become energized and shut down the output until has
cooled to normal operating temperature
Continually exceeding the duty cycle ratings
can cause damage to the welding power source.
NOTICE:
Due to variations that can occur in manufacture products, claimed performance, voltages, ratings, all
capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and
ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.
- 10 BOSS Inverter Mig 165、200 Operating Manual
3.0
OPERATOR CONTROLS
3.01
INVERTER MIG Series controls
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Main Circuit Bleaker— Switching to the ON position energizes the welding power source.
Wire Feed Speed Control.
Voltage Control.
14-Pin Receptacle— Used to connect the wire feeder.
Positive Terminal— 50mm Screw receptacle.
Negative Terminal— 50mm Screw receptacle.
Terminal— Use to connect the torch.
Selector Control— 2T / 4T
Inductance Control.
Meter Selection.
Digital Meter.
Warning Indicator— Activates under the following conditions:
• Input voltage is too low/ too high
• Thermal overload
13. AC Power Indicator— Lights when in the ON position.
14. Input Gas Fitting.
15. Fuse.
- 11 BOSS Inverter Mig 165、200 Operating Manual
16.
17.
18.
19.
110VAC Auxiliary Power.
Ground screw— Ground cable.
Input Power Cable Port.
Burnback (Inside).
Figure 3
Pin
WF2 function
4 inch spool gun function
A
B
Torch switch input
Torch switch input
Torch switch input
Torch switch input
C
Current regulation
D
Current regulation
E
Current regulation
F
G
Short line
Short line
H
Short line
I
Spot switch
J
Spot switch
K
L
Solenoid valve
Solenoid valve
M
WF2 motor
Spool gun motor
N
WF2 motor
Spool gun motor
Short line
Short line
Table 5
WARNING
When the welder is connected to the primary supply voltage, the internal electrical
components maybe at primary potential with respect to earth.
- 12 BOSS Inverter Mig 165、200 Operating Manual
3.02
INVERTER MIG Series Control Methods
Weld Control
MIG/MAG
Description
Yes
2T mode MIG
Yes
4T mode MIG
No
Spot mode MIG
2T Mode
4T Mode
Spot mode
Table 6
3.03
Inverter Mig series selection of weld technology in different weld methods
Weld parameter description
Figure 4
Inverter Mig series front panel with parameter description
Parameter
Description
Welding Current
This parameter sets the welding current.
Burnback Time
MIG only. Burnback time is the difference between the wire feed motor stopping and
switching off of the welding current. The Burnback time allows the electrode wire to
burn out of the molten metal weld pool, to separate the electrode wire from work piece.
Table 7
Weld parameter description for Inverter Mig series
- 13 BOSS Inverter Mig 165、200 Operating Manual
4.0
SET-UP FOR MIG/MAG
Conventional operating procedures apply when using the welding power source, i.e. connect work lead
directly to work piece and connect MIG gun to the power source. Wide safety margins provided by the coil
design ensure that the welding power source will withstand short-term overload without adverse effects. The
welding current range values should be used as a guide only. Current delivered to the arc is dependent on the
welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding
current at any one setting would vary according to the type of electrode in use. The operator should use the
welding current range values as a guide, and then finally adjust the current setting to suit the application.
Figure 5 Set up for Inverter Mig series
WARNING:
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the Primary power supply is switched off.
CAUTION 2:
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
- 14 BOSS Inverter Mig 165、200 Operating Manual
5.0
POWER SUPPLY CONTROLS INDICATORS AND REATURES
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Inverter Mig series front panel
Main Power Switch.
Wire Feed Speed Control.
Voltage Control.
Selector Control— 2T / 4T
Inductance Control.
Meter Selection.
Voltage Indicator.
Speed Indicator.
Amperage Indicator.
Digital Meter.
Warning Indicator.
AC Power Indicator.
- 15 BOSS Inverter Mig 165、200 Operating Manual
5.01
Basic MIG Welding Guide
The welding power supply has two control settings that have to balance. These are the wire speed
control and the voltage control switches. The welding current is determined by the wire speed control, the
current will increase with increased wire speed, resulting in a shorter arc. Less wire speed will reduce the
current and lengthen the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding
current, because the wire speed is not changed.
l When changing to a different electrode wire diameter, different control settings are required. A thinner
electrode wire needs more wire speed to achieve the same current level.
l A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to
suit the electrode wire diameter and dimensions of the work piece.
l If the wire speed is too high for the welding voltage, “stubbing”will occur as the wire dips into the molten
pool. If the wire speed is too slow for the welding voltage, large drops will form on the end of the
electrode wire, causing spatter. Suppose that 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.
5.02
Position of MIG Gun
The angle of MIG gun to the weld has an effect on the width of the weld run.
Figure 7 MIG gun angle
5.03
Distance from the MIG Gun Nozzle to the Work Piece
The electrode stick out from the MIG gun nozzle should be between 2.0mm to 5.0mm. This distance may
vary depending on the type of joint that is being weld.
5.04
Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run.
5.05
Electrode Wire Size Selection
The choice of electrode wire size in conjunction with shielding gas used depends on:
- 16 BOSS Inverter Mig 165、200 Operating Manual
l
l
l
l
l
l
l
Thickness of the metal to be welded.
Type of joint.
Capacity of the wire feed unit and power supply.
The amount of penetration required.
The deposition rate required.
The bead profile desired
The position of welding and cost of the electrode wire.
Weld metal deposition rate is proportional to current density. Current density is defined as the current per
cross sectional area of electrode wire and is normally expressed as amps per mm2. An example is tabled
below.
Electrode Wire Size
Current (A)
Current Density (A/mm2)
Deposition Rate (lbs/hour)
0.9mm (.035”)
200
314
7.0
1.2mm (.045”)
200
177
6.2
Table 8
0.9mm/ 1.2mm wire deposition rate
This demonstrates that where the upper limit of current is limited by the machine capacity and duty cycle,
higher deposition rates therefore greater productivity will be achieved by using smaller electrode wire. The
Inverter Mig series is a particularity efficient MIG welder with the 0.9mm~1.2mm steel wire in spray transfer
mode. 0.9mm wire cost approx. 10% more than 1.2mm but is deposited approx 15% faster.
High current density or smaller diameter wire also gives deeper penetration as shown:
Figure 8
5.06
Wire penetration comparison
Spot Welding Operation
Fit a spot welding nozzle to the MIG gun for consistent spot welding operations. The INVERTER MIG
Series power supply will operate effectively using 0.8~1.2mm electrode wire when spot welding. Penetration
depth is limited when using 0.6mm electrode wire for spot welding. Set the controls as follows for spot
welding:
1. Coarse & fine voltage selector switches and wire speed control.
Select higher voltage selector switch positions and set the wire speed control between 354 to 590ipm
(9~15 meters/ minute)
2. Mode selector switch.
3. Spot Time.
4. Burnback Time.
- 17 BOSS Inverter Mig 165、200 Operating Manual
6.0
MAINTENANCE
If this equipment does not operate properly, stop work immediately and investigate the cause of the
malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical
work must be performed by an electrician or other person properly trained in servicing electrical equipment.
Do not permit untrained persons to inspect, clean or repair this equipment. Use only recommended
replacement parts when servicing this machine.
Periodically clean the inside of the welding power source by using clean dry compressed air of not over
25psi as normal preventive maintenance. At the time of the cleaning, a full inspection of the welding machine
and setup should be performed. Check warning labels on the machine for readability; replace if necessary.
Check input and output connections as well as frame ground connections to the machine to insure that they
are tight and the wires are not frayed or overheated. Inspect internal wiring of machine for loose or frayed
connections; tighten or repair as necessary. It would also be advisable to check connections to wire feeders,
fixtures, etc., at this time. Any damaged cable or hoses should be replaced.
DANGER: HIGH VOLTAGE is present internally even with the control power switch in the
OFF position. Before inspecting, cleaning, or servicing, disconnect and lock out input power to
the power source.
7.0
BASIC TROUBLESHOOTING
WARNING
There are extremely dangerous voltages and power levels present inside this product.
Do not attempt to open or repair unless you are an accredited BOSS service agent and
you have had training in power measurements and troub leshooting techniques.
If major complex subassemblies are faulty, then the welding power source must be returned to an
accredited BOSS service agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or
knowledge.
7.01
Check the item and excrescent phenomenon exclusion method
- 18 BOSS Inverter Mig 165、200 Operating Manual
Troubleshooting Guide
Fault
Cause
Remedy
1. The AC power indicator light is
not lit and welding arc can not
be established.
1. No power input or main power
switches damage.
2. Indicator damage.
1. Check input power or replace
main power switch.
2. Replace indicator light.
2. The AC power indicator light on
and welding arc can not be
established.
1. Input voltage unstable.
2. Diode PCB damage.
1. Connect stabilizer or reset power
switch.
2. Repair or replace.
3. The warning indicator light on.
Over load.
Reduce current or wait moment.
a. No gas flow
No wire feed
No output
1. MIG torch plug is not insert into 1. Insert the plug correctly, and
the socket or the connect is
rotate it clockwise.
bad.
2. MIG torch damage (diagnose 2. Repair or replace MIG torch.
method: make the welding
machine control socket two
pins short circuit, the faulty
disappear).
3. Wire feeder plug is not insert 3. Insert the plug correctly, and
into the socket or the connect
rotate it clockwise.
condition is bad.
b. No gas flow
Have wire feed
Have output
1.
2.
3.
4.
c. Have gas flow
Have wire feed
No output
1. Disconnect the work piece to 1. Reconnect the ground cable and
the work ground cable.
tighten the work piece.
2. Wire feed control PCB damage. 2. Repair or replace.
4. Turn on
torch
control
switch
The gas line is not turn on.
The MIG torch damage.
The solenoid damage.
Wire feed control PCB damage.
Turn on the gas system.
Repair or replace.
Repair or replace.
Repair or replace.
3. Main PCB damage.
1. Diode PCB bad connect.
2. Relay PCB bad connect.
1. Repair or replace the MIG torch.
2. Read this manual carefully and
set up correctly.
3. Repair or replace.
1. Repair or replace.
2. Repair or replace.
7. Arc start difficult or often break
off.
1. The power supply voltage is too
low or the cable is too thin.
2. Control board damage.
3. The contact tip damage.
4. The work piece bad connect.
5. The drive roller damage.
6. The torch lead damage.
1. Connect a stabilizer or increase
the thickness of the power cable.
2. Repair or replace.
3. Repair or replace.
4. Repair or replace.
5. Replace
6. Replace
8. The maximum output welding
current can not achieved in the
rated input voltage.
1. Control board damage.
1. Repair or replace.
2. Wire feed control PCB damage. 2. Repair or replace.
9. The current decrease in the
weld process.
Faulty cable connected to work Make sure the cable positive connect
piece.
to the work piece correctly.
5. Faulty welding arc control.
6. The arc weld has no output.
1. The MIG torch damage.
2. Faulty setting.
1.
2.
3.
4.
Table 9
- 19 BOSS Inverter Mig 165、200 Operating Manual
7.02
Solving Problems Beyond the Welding Terminals
The general approach to fix gas metal arc welding (GMAW) problems is to start at the wire spool then
work through to the MIG gun. There are two main areas where problems occur with GMAW:
a) Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems
from some contaminant within the molten weld pool which is in the process of escaping during solidification of
the molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface.
Porosity can be reduced by checking the following points:
l Gas cylinder contents and flow meter
Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 15 liters per
minute (0.5 cubic feet per minute)
l Gas leaks
Check for gas leaks between the regulator/ cylinder connection and in the gas hose to the power
supply.
l Internal gas hose in the power supply
Ensure the hose from the solenoid valve to the MIG gun adaptor has not fractured and that it is
connected to the MIG gun adaptor.
l Welding in a windy environment
Shield the weld area from the wind or increase the gas flow.
l Welding dirty, oily, painted oxidized or greasy plate.
Clean contaminates off plate.
l Distance between the MIG gun
Keep the distance between the MIG gun nozzle and the work piece to a minimum. Refer to distance
from the MIG gun nozzle to the work piece in 5.03.
l Maintain the MIG gun in good work order
Ensure that the gas holes are not blocked and gas is exiting out of the gun nozzle. Refer to the
WARNING.
Do not restrict gas flow by allowing spatter to build up inside the MIG gun nozzle.
Check that the MIG gun O-rings are not damaged.
WARNING: Disengage the drive roll when testing for gas flow by ear.
b) Inconsistent wire feed
Wire feeding problems can be reduced by checking the following points:
l Wire spool brake is too tight
Feed roller driven by motor in the cabinet will slip.
l Wire spool brake is too loose
Wire spool can unwind and tangle.
l Worn or incorrect feed roller size
- 20 BOSS Inverter Mig 165、200 Operating Manual
l
l
l
l
l
Use “U”groove drive feeder roller matched to the aluminum wire size you are welding.
Use “V’
”groove drive feeder roller matched to the steel wire size you are welding.
Use “knurled V”’groove drive feeder roller matched to the flux cored wire size you are welding.
Mis-alignment of inlet/ outlet guides
Wire will rub against the mis-aligned guides and reduces wire feed ability.
Liner blocked with debris
Debris is produced by the wire passing through the feed roller, if excessive pressure is applied to
the pressure roller adjuster.
Debris can also be produced by the wire passing through an incorrect feed roller groove shape or
size.
Debris is fed into the liner where it accumulates thus reducing wire feed ability.
Incorrect or worn contact tip
The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too
large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the
contact tip.
When using soft electrode wire such as aluminum it may become jammed in the contact tip due to
expansion of the wire when heated. A contact tip designed for soft electrode wires should be used.
Poor work lead contact to work piece
If the work lead has a poor electrical contact to the work piece then the connection point will heat up
and result in a reduction of power at the arc.
Bent liner
This will cause friction between the wire and the liner thus reducing wire feed ability.
- 21 BOSS Inverter Mig 165、200 Operating Manual
7.03
Weld Problems
Fault
1. Undercut
2. Lack of penetration
3. Lack of fusion
Cause
Remedy
A
Welding arc voltage too high.
B
C
Incorrect gun angle.
Excessive heat input.
A
Welding current too low.
B
Joint preparation too narrow
or gap too tight.
C Shielding gas incorrect.
Voltage too low.
A Voltage too high.
4. Excessive spatter
B Voltage too low.
A Incorrect voltage and current
settings.
Convex, voltage too low.
Concave, voltage too high.
5. Irregular weld shape B Wire is wandering.
C Incorrect shielding gas.
D Insufficient or excessive heat
input.
A Weld beads too small.
B Weld penetration narrow and
deep.
6. Welding cracking
C Excessive weld stress.
D Excessive voltage.
E
7. Cold weld puddle
Cooling rate too fast.
A
B
Faulty rectifier unit.
Loose
welding
connection.
C Low primary voltage.
cable
Table 10
- 22 BOSS Inverter Mig 165、200 Operating Manual
A
Reduce voltage by reducing the voltage
selection switches position or increase the
wire feed speed.
B Adjust angle.
C Increase the gun travel speed and/ or
reduce welding current by reducing the
voltage selection switches position or
reducing the wire feed speed.
A Increase welding current by increasing
wire feed speed and increasing voltage
selection switch position.
B Increase the joint angle or gap.
C Change to a gas which gives higher
penetration.
Increase voltage by increasing voltage
selection switch position.
A Lower voltage by increasing wire speed
control or reducing the voltage selection
switches.
B Raise voltage by reducing wire speed
control or increasing the voltage selection
switches.
A Adjust voltage and current by adjusting
the voltage selection switches and the
wire speed control.
B Replace the contact tip.
C Check shielding gas.
D Adjust the wire speed control or voltage
selection switches.
A Decrease the travel speed.
B Reduce current and voltage and increase
MIG gun travel speed or select a lower
penetration shielding gas.
C Increase weld metal strength or revise
design.
D Decrease the voltage by reducing the
voltage selection switches.
E Slow the cooling rate by preheating part to
be weld or cool slowly.
A Have an accredited BOSS service agent
to test then replace the faulty component.
B Check all welding cable connections.
C Contact supply authority.
7.04
Power Supply Problems
Fault
1.
2.
3.
4.
5.
6.
7.
8.
9.
Input
power
supply
voltage is ON. Indicator
light is not lit and welding
arc
can
not
be
established.
Input power indicator
light is not lit and welding
arc
can
not
be
established.
Input power supply is ON
and indicator light is lit
but when the gun trigger
switch is depressed
nothing happens.
Input
power
supply
voltage is ON, no wire
feed but gas flows from
the MIG gun when the
gun trigger switch is
depressed.
Wire feeds when the gun
trigger
switch
is
depressed but arc can
not be established.
Wire continues to feed
when the gun trigger
switch is released.
Jerky wire feed.
No gas flow.
Gas flow continues after
the gun trigger switch
has been released.
Cause
Remedy
A Primary fuse is blown.
B Broken connection in primary
circuit.
A
B
Replace Primary fuse.
Have an accredited BOSS service
agent check primary circuit.
Indicator light is open circuit.
Have an accredited BOSS service agent
replace indicator light.
Gun trigger switch leads are
disconnected.
Reconnect.
A Electrode wire stuck in conduit
liner or contact up (burn-back
jam).
B Faulty control PCB.
A
B
Check for clogged/ kinked MIG gun
conduit or worn contact tip, replace
faulty components.
Have an accredited BOSS service
agent investigate the faulty.
Poor or no work lead connection.
Clean work clamp area and ensure good
electrical contact.
The mode selector switch has
been set to 4T (latch operation).
Set the mode selector switch to 2T
(normal operation).
A Worn or dirty contact tip.
B Worn feed roll.
C Excessive back tension from
wire reel hub.
D Worn, kinked or dirty conduit
liner.
A Gas hose is cut.
B Gas
passage
contains
impurities.
A Replace.
B Replace.
C Reduce brake tension on spool hub.
D Clean or replace conduit liner.
C Gas regulator turned off.
Replace or repair.
Disconnect gas hose from the rear
of Inverter Mig series or then raise
gas pressure and blow out the
impurities.
C Turn on the gas regulator.
Gas valve has jammed open due
to impurities in the gas or gas line.
Have an accredited BOSS service agent
repair or replace gas valve.
Table 11
- 23 BOSS Inverter Mig 165、200 Operating Manual
A
B
8.0
PART LIST
- 24 BOSS Inverter Mig 165、200 Operating Manual
Figure 9
- 25 BOSS Inverter Mig 165、200 Operating Manual
QTY.
Sequence
Order No
Name
Inverter Mig
165
1
Inverter Mig
200
1
1
3KITP000505052
BOARD,PCB,CONTROL (7.820.507A-03)
2
3KITP000206014
OUTPUT 200M
1
1
2-1
3KITP000506010
BOARD,PCB,MOSFET (7.820.052-03)
1
1
2-2
3KITP000506024
BOARD,PCB,DIODE (7.827.002A-01)
1
1
2-3
2HS7061048
HEATSINK LEFT-LOWER (Inside)
1
1
2-4
2HS7061049
HEATSINK LEFT-UPPER-A (Inside)
1
1
2-5
2HS7061050
HEATSINK LEFT-UPPER-B (Inside)
1
1
2-6
2HS7061046
HEATSINK RIGHT-UPPER (Inside)
1
1
2-7
2HS7061047
HEATSINK RIGHT-LOWER (Inside)
1
1
2-8
2FPPM8610007
BRACKET MOUNTING AL
1
1
2-9
4KNCR0T95
THERMOSTAT SD302
2
2
2-10
4VQK2SK2837
MOSFET 2837
20
20
2-11
4V2HMM20FU020BC812
DIODE ULTRA FAST RECOVERY
16
16
2-12
4LZQ4X2X5
HOSE FERRITE 4*2*5
48
48
2-13
2FP8647002
INSULATOR II (Inside)
27
27
2-14
2FP8647003
INSULATOR I (Inside)
1
1
2-15
2FPBM8610038
BRACKET,HEATSINK MOUNTING (Inside)
2
2
2-16
2FPBM8610039
BRACKET,HEATSINK MOUNTING I
4
4
2-17
2FPBM8610040
BRACKET,HEATSINK MOUNTING II
2
2
2-18
2FPPP8610117
BRACKET,MOSFET/DIODE (8.610.117)
15
15
2-19
2FPPP8610118
BRACKET,MOSFET/DIODE (8.610.118) (Inside)
2
2
2-20
2FP7840020
INSULATOR,HEATSINK (Inside)
1
1
2FP7854011
SPACER,NYLON 凹 D5 (Inside)
18
18
4BFTDQ001D5
SPACER,NYLON 凸 D5 (Inside)
18
18
2FP7854012
SPACER,NYLON 凹 D3 (Inside)
6
6
4BFTDQ003D3BK
SPACER,NYLON 凸 D3 (Inside)
6
6
2FP7854015
SPACER,NYLON 凹 D4 (Inside)
2
2
4BFTDQ003D3BK
SPACER,NYLON 凸 D3 (Inside)
2
2
2-24
3KITP002001010
BOARD,PCB,RECTIFIER (7.827.007)
2
2
3
3KITP000107008
BOARD,PCB,POWER (7.823.003-01)
1
1
4
3KITP002601202
BOARD,PCB,RELAY-INPUT (7.828.009)
1
1
5
3KITP000112005
VALVE DC24V
1
1
6
3KITP002701030
BOARD,PCB,FILTER (7.820.006C-02) (Inside)
1
1
7
4SNOCS300B
SENSOR 300B
1
1
8
3KITP002706016
BOARD,PCB,DISPLAY-B (7.824.002B-02)
1
1
9
3KITP002706011
BOARD,PCB,DISPLAY-A (7.824.002A)
1
1
10
3KITP003403000
BOARD,PCB,CONTROL-WIRE DRIVE(7.820.506A-02)
1
1
11
3KITP002205030
BOARD,PCB,RELAY (7.828.011-01)
1
1
12
2BAR65000
SUPPORT SPOOL
1
1
2-21
2-22
2-23
- 26 BOSS Inverter Mig 165、200 Operating Manual
13
3BB7725083
BUS BAR,POSITIVE
2
2
14
3BB7725084
BUS BAR,POSITIVE
1
1
15
3BB7725085
BUS BAR,OUTPUT
1
1
16
3EER22006
ASSY,OUTPUT INDUCTOR
1
1
17
2LAC8807133
OVERLAY CONTROL 200M
1
1
18
2LAF8802164
LABEL POWER 200M BOSS
18
1
LABEL POWER 165M BOSS
1
19
2LAU8803009
LABEL (+)
1
1
20
2LAU8803010
LABEL (-)
1
1
21
2LAN8808306
LABEL MANUFACTURERS RATING 200M BOSS
21
1
LABEL MANUFACTURERS RATING 165M BOSS
1
22
2LAM8800003
LABEL GROUND
1
1
23
2LAU8801001
LABEL GAS INPUT
1
1
24
2LAM8800001
LABEL VOLTAGE INPUT 240V 1PH
1
1
25
2LAM8806009
LABEL FUSE
1
1
26
2LAM8806020
LABEL AUXILIARY POWER 115V 1PH
1
1
27
2LAW8805002
LABEL WARNING
1
1
28
2LAW8805004
LABEL WARNING
1
1
29
2LAC8807053
LABEL BURNBACK
1
1
30
2FPB6123016
BASE
1
1
31
2FPBG6153001
PANEL CENTER
1
1
32
2FPUT8038029
PANEL UPPER TRAY
1
1
33
2FBM8604059
BRACKET DISPLAY-B MOUNTING (Inside)
1
1
34
2FBM8604073
BRACKET 14 PIN MOUNTING (Inside)
1
1
35
2FP7854004
INSULATOR BULKHEAD FRONT
2
2
36
2FP7854008
INSULATOR BULKHEAD REAR
2
2
37
2GS50CC001FP
RECEPTACLE,TWIST LOCK(FEMALE) POWER
2
2
38
4KCD221BK
SWITCH
1
1
39
4SXJPG13R5
BUSHING,STRAIN RELIEF PG13.5
1
1
40
2FP7854018
PROTECTION FOR EURO CONNECTOR
1
1
41
4KCD221BK
KNOB
3
3
42
4CC010206
TERMINAL 2*5
1
1
43
4FUSH15X250XD6
FUSE HOLDER
1
1
44
4XSP6BH3
SOCKET 115V
1
1
45
4FANCSA1725
FAN COVER
1
1
46
4WRKSSBS26
BUSHING SNAP BS26 (Inside)
2
2
47
4WRNB1216
BUSHING SNAP (Inside)
1
1
48
4JFT35X50
MOUNT NPRN
4
4
49
2FP7854018
INSULATOR WIRE DRIVE
2
2
50
4FAN001SA1725
FAN
1
1
51
4FUSH5A
FUSE LINE HOLDER
1
1
- 27 BOSS Inverter Mig 165、200 Operating Manual
52
4ZK76ZY01
WIRE DRIVE
1
1
53
4EER400112
TRANSFORMER CONTROL BOD300
1
1
54
4WTH1A2W5K
POTENTIONMETER 2W 5K
2
2
55
4WTH1A2W100K
POTENTIONMETER 2W 100K
1
1
56
4KNX202
SWITCH KNX202
2
2
57
481CC3KV103
CAPACITOR 3KV103 (Inside)
1
1
58
2BGER90620
EURO CONNECTOR
1
1
59
4WP143102A
RECEPTACLE 14 PIN
1
1
60
4RX27D20W0R47H
RESISTOR 20W 0.47 OHM
1
1
61
8HPVC5X8BK001
GAS HOSE 5*8
0.82M
0.82M
62
4RX27D50W500H
RESISTOR 50W 500 OHM
1
1
63
2FPPT8040030Y
PANEL TOP
1
1
64
2FPPT6170014Y
PANEL LEFT SIDE UPPER
1
1
65
2FPPT8048017Y
PANEL LEFT SIDE LOWER
1
1
66
4HDL00004
HANDLE
1
1
67
2PST8634002
LATCH SLIDE
2
2
68
2LAW8805000
LABEL WARNING
1
1
69
2LAS8809040
LABEL BOSS
2
2
BRACKET,MOUNTING (8.604.059) (Inside)
1
1
70
Table 12
9.0
9.1
9.2
9.3
9.4
9.5
9.6
REMARK
Welding machines rear panels meet the plume to have good to turn on the earth
grounding, by guarantees the welder safety. When welder operation, should wear
protects the mirror, the glove, puts on protects the clothing.
When the electrical network voltage is higher than 240V/260V, the out-put will appear the
class, the overload, the welding machine automatically has stopped outputting and giving
the red candle demonstration warning.
Ambient temperatures high when big electric current long time continuous working, the
welding machine has stopped because of the heat outputting, gets down until the
temperature drop only then restores.
When welding machines do not use temporarily, its depository should maintain dryly,
cleanly. The environment relative humidity is not bigger than 85%.
Storing ambient temperature is -25℃~ +55℃.
When long -time does not use, every two months should electrify a time, a humidity month
of every two week should electrify use a time, by use own thermal row of tide.
- 28 BOSS Inverter Mig 165、200 Operating Manual