Boss ARC 140 Specifications

MODEL
•
•
BOSS ARC 140VRD
BOSS ARC 160VRD
Operating Manual
(Owner’
s Manual)
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
First Edition
September, 2008
Manual No. B0803
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 Specifications----------------------------------------------------------------------------------------------9
2.03 Duty cycle--------------------------------------------------------------------------------------------------9
3.0
OPERATOR CONTROLS-------------------------------------------------------------------------------10
3.01 BOSS ARC VRD Series controls-------------------------------------------------------------------10
3.02 Weld parameter description--------------------------------------------------------------------------11
4.0
SET-UP FOR MMA (STICK) AND GTAW (TIG)----------------------------------------------------12
4.01 Stick welding---------------------------------------------------------------------------------------------13
4.02 DC TIG welding-----------------------------------------------------------------------------------------13
5.0
POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------14
6.0
BASIC TIG WELDING GUIDE--------------------------------------------------------------------------15
6.01 Electrode Polarity---------------------------------------------------------------------------------------15
6.02 Tungsten Electrode Current Ranges---------------------------------------------------------------15
6.03 Tungsten Electrode Types----------------------------------------------------------------------------15
6.04 Guide for Selecting Filler Wire Diameter----------------------------------------------------------15
6.05 Shielding gas selection--------------------------------------------------------------------------------16
6.06 TIG welding parameters for low carbon & low alloy steel pipe-------------------------------16
6.07 Welding parameters for steel------------------------------------------------------------------------16
7.0
BASIC ARC WELDING GUIDE------------------------------------------------------------------------17
7.01 Electrode polarity---------------------------------------------------------------------------------------17
7.02 Effects of stick welding various materials---------------------------------------------------------17
8.0
MAINTENANCE--------------------------------------------------------------------------------------------18
9.0
BASIC TROUBLESHOOTING-------------------------------------------------------------------------19
9.01 Check the item and excrescent phenomenon exclusion method---------------------------19
9.02 TIG welding problems---------------------------------------------------------------------------------20
9.03 Stick welding problems--------------------------------------------------------------------------------21
9.04 Power source problems-------------------------------------------------------------------------------22
10.0 PART LIST---------------------------------------------------------------------------------------------------23
11.0 REMARK-----------------------------------------------------------------------------------------------------27
-1BOSS ARC 140VRD、160VRD 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 ARC 140VRD、160VRD 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 ARC 140VRD、160VRD 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 ARC 140VRD、160VRD 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 ARC 140VRD、160VRD 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 ARC 140VRD、160VRD Operating Manual
2.0
INSTALLATION RECOMMENDATION
Installation Environment
BOSS ARC VRD 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
Model
Minimum primary
current circuit size
Current & Duty Cycle
TIG
STICK
TIG
STICK
BOSS ARC 140VRD
Minimum
5mm2
220V/19.5A
240V/17.9A
220V/27A
240V/24.8A
140A/15.6V@60%
125A/15V@100%
140A/25.6V@60%
110A/24.4V@100%
BOSS ARC 160VRD
Minimum
6mm2
220V/22A
240V/20.2A
220V/33.5A
240V/30.7A
160A/16.4V@100%
160A/26.4V@60%
125A/25V@100%
Table 1
Primary current circuit sizes to achieve maximum current
-7BOSS ARC 140VRD、160VRD 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
50 Amps
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
-8-
BOSS ARC 140VRD、160VRD Operating Manual
2.02
Specifications
MODEL
BOSS ARC 140VRD
BOSS ARC 160VRD
Input voltage and frequency and phases
220/240V 50/60Hz 1ph
220/240V 50/60Hz 1ph
TIG
4.3KVA
4.8KVA
STICK
6.0KVA
7.4kVA
Max current
140A
160A
Output current range
10~140A
10~160A
Open circuit voltage
56/61V
56/61V
Duty cycle at 40℃
60%
60%
Weight
9.5kg
12kg
Dimensions (mm)
370×150×245
420×160×265
KVA @ max output
Table 3
2.03
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.
-9BOSS ARC 140VRD、160VRD Operating Manual
3.0
OPERATOR CONTROLS
3.01
BOSS ARC VRD Series Controls
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Welding Current Control— — Used for regulating to welding current.
Warning Indicator
AC Power Indicator
Main Power Switch
Positive (+) Socket— — TIG connect the work lead/ MMA connect the electrode holder.
Negative (-) Socket— — TIG connect the TIG torch/ MMA connect the work lead.
Input Power Cable
Ground Screw
VRD Indicator
WARNING
When the welder is connected to the primary supply voltage, the internal electrical
components maybe at primary potential with respect to earth.
- 10 BOSS ARC 140VRD、160VRD Operating Manual
3.02
Weld parameters description
Figure 3
BOSS ARC VRD Series front panel with parameter description
Parameter
Welding Current
Description
This parameter sets the welding current.
Table 4
Weld parameter description for BOSS ARC VRD Series
- 11 BOSS ARC 140VRD、160VRD Operating Manual
4.0
SET-UP FOR MMA (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the welding power source, i.e. connect work lead
directly to work piece and welding cable is used to electrode holder. 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 4 Set up for BOSS ARC VRD 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.
- 12 BOSS ARC 140VRD、160VRD Operating Manual
4.01
Stick welding
l
l
l
l
Connect work lead to negative terminal.
Connect electrode lead to positive terminal.
Switch machine on.
Set welding current control (see table 5).
Workpiece thickness mm
0.5-2.0
2.0-5.0
5.0-7.0
Electrode diameter mm
1.0-2.0
2.0-3.2
3.2-4.0
Welding current(A)
10-50
50-150
150-250
Table 5
4.02
DC TIG welding
l
l
l
l
l
Connect work lead to positive terminal.
Connect TIG torch to negative terminal.
Switch machine on.
Set welding current control (see table 6).
Use TIG torch with value control.
Workpiece
thickness (mm)
Tungsten
diameter (mm)
Welding current
(A)
0.3-0.5
1-1.6
5-30
0.5-1.2
1.6-2
10-50
1.2-1.6
4-8
1.2-2
1.6-2
10-50
1.2-1.6
4-8
1.2-2
1.6-2
30-70
1.6-2.0
6-9
2-4
2-4
60-100
1.6-2.0
7-10
4-6
3-4
100-200
2.0-2.5
1-15
Table 6
- 13 BOSS ARC 140VRD、160VRD Operating Manual
Filler wire
diameter (mm)
Argon Gas flow
(L/min)
3-8
5.0
POWER SUPPLY CONTROLS INDICATORS AND REATURES
Figure 5
1.
2.
3.
4.
BOSS ARC VRD Series front panel
Welding currents control— — Uses in adjusting the welding current.
VRD indicator.
Warning indicator— — Red colored light instruction welding machine overload.
AC power indicator— — Green colored light instruction power source is normal.
- 14 BOSS ARC 140VRD、160VRD Operating Manual
6.0
BASIC TIG WELDING GUIDE
6.01
Electrode Polarity
Connect the TIG torch to the - / torch terminal and the work lead to the + / work terminal for direct current
straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows
limited wear of the electrode since 70% of the heat is concentrated at the work piece.
6.02
Tungsten Electrode Current Ranges
Electrode Diameter (mm)
DC current (A)
1.0
30— 60
1.6
60— 115
2.4
100— 165
3.2
135— 200
4.0
190— 280
4.8
250— 340
Table 7
6.03
Current ranges for varies tungsten electrode sizes
Tungsten Electrode Types
Tungsten type
(Ground finish)
Welding Application
Features
Color
code
Thoriated 2%
DC welding of mild steel, stainless Excellent arc starting, Long life, high
steel and copper
current carrying capacity
Red
Ceriated 2%
DC welding of mild steel, stainless Longer Life, More stable arc, Easier
steel, copper, aluminium, magnesium starting,
Wider
current
range,
and their alloys
Narrower more concentrated arc
Grey
Table 8
6.04
Tungsten electrode types
Guide for Selecting Filler Wire Diameter
Filler wire diameter
DC current range (Amps)
1.6
20— 90
2.4
65— 115
3.2
100— 165
4.8
200— 350
Table 9
Filler wire selection guide
Notice:
The filler wire diameter specified in Table 9 is a guide only, other diameter wires may be used
according to the welding application.
- 15 BOSS ARC 140VRD、160VRD Operating Manual
6.05
Shielding gas selection
Alloy
Shielding gas
Aluminium & alloys
Argon
Carbon steel
Argon
Stainless steel
Argon
Nickel alloy
Argon
Copper
Argon
Titanium
Argon
Table 10
6.06
Shield gas selection
TIG welding parameters for low carbon & low alloy steel pipe
Tungsten type &
diameter
Current range DC
(Amperes)
Filler rod for root pass
Thoriated 2%
3/32”(2.4mm)
120— 170
Yes
Thoriated 2%
3/32”(2.4mm)
100— 160
Yes
Thoriated 2%
3/32”(2.4mm)
90— 130
No
Table 11
6.07
Joint preparation
TIG welding parameters for low carbon & low alloy steel pipe
Welding parameters for steel
Base metal
thickness
(mm)
DC current
for mild
steel (A)
35— 45
40— 50
DC current
for stainless
steel (A)
20— 30
25— 35
Tungsten
diameter
(mm)
Filler rod
diameter (if
require) (mm)
Argon gas
flow rate
(litres/min)
Joint type
1.0
1.6
5— 7
butt/ corner
lap/ fillet
1.2
45— 55
50— 60
30— 45
35— 50
1.0
1.6
5— 7
butt/ corner
lap/ fillet
1.6
60— 70
70— 90
40— 60
50— 70
1.6
1.6
7
butt/ corner
lap/ fillet
3.2
80— 100
90— 115
65— 85
90— 110
1.6
2.4
7
butt/ corner
lap/ fillet
4.8
115— 135
140— 165
100— 125
125— 150
2.4
3.2
10
butt/ corner
lap/ fillet
6.4
160— 175
170— 200
135— 160
160— 180
3.2
4.0
10
butt/ corner
lap/ fillet
1.0
Table 12
DC TIG welding parameters
- 16 -
BOSS ARC 140VRD、160VRD Operating Manual
7.0
BASIC ARC WELDING GUIDE
7.01
Electrode polarity
Stick electrodes are generally connected to the “+”terminal and the work lend to the “-“terminal but if in
doubt consult the electrode manufacturers literature.
7.02 Effects of stick welding various materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld
area, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone
and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using
higher current settings, using larger electrodes size, short runs for larger electrode deposits or tempering in a
furnace.
Manganese steels
The effect on manganese steel slow of cooling from high temperature is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip
welding to distribute the heat.
Cast iron
Most types of cast iron, expect white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by gas held in this type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of copper, so making preheating of heavy
sections necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc welding electrodes are classified into a number of groups depending on their applications. There are
a great number of electrodes used for specialized industrial purposes, which are not of particular interest for
everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for
welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast
majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of
welding machines.
Metals being joined
Electrode
Comments
Ideal electrodes for all general purpose work. Features
mild steel
6013
include out standing operator appeal, easy arc starting and
low spatter.
All positional electrodes for use on mild and galvanized
mild steel
7014
steel furniture, plates, fences, gates, pipes and tanks etc.
Especially suitable for vertical-down welding.
cast iron
nickel 99%
stainless steel
318L-16
copper, bronze, brass etc.
bronze
5.7ERCUSI-A
high alloy steels, dissimilar
metals, crack resistance, all
hard-to-weld jobs
312-16
Table 13
Suitable for joining all cast irons except white cast iron.
High corrosion resistance. Ideal for dairy work, etc. On
stainless steels.
Easy to use electrode for marine fittings, water taps and
valves, water trough float arms, etc. Also for joining copper
to steel and for bronze overlays on steel shafts.
It will weld most problematical jobs such as springs, shafts,
broken joins mild steel to stainless and alloy steels. Not
suitable for Aluminum.
Types of Electrodes
- 17 -
BOSS ARC 140VRD、160VRD Operating Manual
8.0
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.
- 18 BOSS ARC 140VRD、160VRD Operating Manual
9.0
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 troubleshooting 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.
9.01 Check the item and excrescent phenomenon exclusion method
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. Primary fuse is blown.
3. Indicator damage.
4. Relay PCB damage (for ARC
160VRD).
5. Indicator light is open circuit.
1. Check input power or replace
main power switch.
2. Replace primary fuse.
3. Replace indicator light.
4. Replace relay PCB.
2. The AC power indicator light on 1. Input voltage unstable.
and welding arc can not be
established.
2. Diode PCB damage.
1. Over load.
3. The warning indicator light on.
2. MOSFET damage.
4. MMA (STICK) mode no circuit
output.
1. Function switch select to the MMA
mode position.
2. Relay PCB damage.
3. MOSFET damage.
1. Power PCB damage.
5. MMA (STICK) mode unstable
2. Diode PCB damage.
welding arc.
3. Control PCB damage.
6. Fan does not run.
1. Power PCB damage.
2. Fan motor damage.
3. Relay PCB damage.
Table 14
- 19 -
BOSS ARC 140VRD、160VRD Operating Manual
5. Replace indicator light.
1. Connect stabilizer or reset power
switch.
2. Replace diode PCB.
1. Reduce current or wait moment.
2. Replace MOSFET.
1. Select to MMA mode.
2. Replace relay PCB.
3. Replace MOSFET.
1. Replace power PCB.
2. Replace diode PCB.
3. Replace control PCB.
1. Replace power PCB.
2. Replace fan motor.
3. Replace relay PCB.
9.02
TIG welding problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description
1. Excessive bead build-up
or poor penetration or
poor fusion at edges of
weld.
2. Weld bead too wide and
flat or undercut at edges
of weld or excessive
burn through.
3. Weld bead too small or
insufficient penetration
or ripples in bead are
widely spaced apart.
4. Weld bead too wide or
excessive bead build up
or excessive penetration
in butt joint.
5. Uneven leg length in
fillet joint.
6. Dirty weld pool.
7. Electrode
melts
or
oxidizes when an arc is
struck.
8. Poor weld finish.
9. Arc flutters during TIG
welding.
10. Welding arc can not be
established.
Possible Cause
Remedy
Welding current is too low.
Increases weld current, and/ or faulty
joint preparation.
Welding current is too high.
Decreases weld current.
Travel speed too fast.
Reduce weld speed.
Travel speed too low.
Increase travel speed.
Wrong placement of filler rod.
Re-position filler rod.
A Electrode contaminated through A Clean the electrode by grinding off
contact with work piece or filler rod
the contaminates.
material.
B Gas contaminated with air.
B Check gas lines for cuts and loose
fitting or change gas cylinder.
A Electrode is connected to the “+” A Connected the electrode to the “-”
terminal.
terminal.
B No gas flowing to welding region.
B Check the gas lines for kinks or
breaks and gas cylinder contents.
C Torch is clogged with dust.
C Clean torch.
D Gas hose is cut.
D Replace gas hose.
E Gas passage contains impurities.
E Dismantle a soft tube from the
torch then raise gas pressure and
blow out impurities.
F Gas regulator turned off.
F Turn on.
G Torch valve is turned off.
G Turn on.
H The electrode is too small for the H Increase electrode diameter or
welding current.
reduce the welding current.
Increase gas flow or check gas line for
Inadequate shielding gas.
gas flow problems.
A Tungsten electrode is too large for A Select the right size electrode.
the welding current.
Refer to basic TIG welding guide.
B Absence of oxides in the weld pool. B Refer basic TIG welding guide for
ways to reduce arc flutter.
A Work clamp is not connected to the A Connect the work clamp to the
work piece or the work/ torch leads
work piece or connect the work/
are not connected to the right
torch leads to the right welding
welding terminals.
terminals.
B Torch lead is disconnected.
B Connect it to the “−”terminal.
C Gas flow incorrectly set, cylinder C Select the right flow rate, change
empty or the torch valve is off.
cylinders or turn torch valve on.
- 20 -
BOSS ARC 140VRD、160VRD Operating Manual
11. Arc start is not smooth.
A Tungsten electrode is too large for A Select the right size electrode.
the welding current.
Refer to basic TIG welding guide.
B The wrong electrode is being used B Select the right electrode type.
for the welding job.
Refer to basic TIG welding guide
C Gas flow rate is too high.
C Select the correct rate for the
welding job.
D Incorrect shielding gas is being D Select the right shielding gas.
used.
Refer to Basic TIG Welding Guide.
E Poor work clamp connection to E Improve connection to work piece.
work piece.
Table 15
9.03
Stick welding problems
Description
Cause
Remedy
A Electrodes are damp.
1 Gas
pockets
or
B Welding current is too large.
voids in weld metal
C Surface impurities such as: oil,
(Porosity).
grease, paint, etc.
A Rigidity of joint.
2 Crack occurring in
weld metal soon
after
solidification B Insufficient throat thickness.
commences.
C Cooling rate is too high.
3 A gap is left by A Welding current is too low.
failure of the weld B Electrode too large for joint.
metal to fill the root C Insufficient gap.
of the weld.
D Incorrect sequence.
A Small electrodes used on heavy cold
4 Portions of the weld
plate.
run do not fuse to B Welding current is too low.
the surface of the C Wrong electrode angle.
metal or edge of the
joint.
D Travel speed of electrode is too high.
E Scale or dirt on joint surface.
A Non-metallic particles may be trapped
in undercut from previous run.
B Joint preparation too restricted.
C Irregular deposits allow slag to be
5 Non-metallic
trapped.
particles are trapped D Lack of penetration with slag trapped
beneath weld bead.
in the weld metal
(slag inclusion).
E Rust or mill scale is preventing full
fusion.
F Wrong electrode for position in which
welding is done.
Table 16
- 21 BOSS ARC 140VRD、160VRD Operating Manual
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow greater
build up in throat.
C Preheat plate and cool slowly.
A Increase welding current.
B Use smaller diameter electrode.
C Allow wider gap.
D Use correct build-up sequence.
A Use larger electrodes and preheat
the plate.
B Increase welding current.
C Adjust angle so the welding is
directed more into the base metal.
D Reduce travel speed of electrode.
E Clean surface before welding.
A If bad undercut is present, clean slag
out and cover with a run from a
smaller diameter electrode.
B Allow for adequate penetration and
room for cleaning out the slag.
C If very bad, chip or grind out
irregularities.
D Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E Clean joint before welding.
F Use electrodes designed for position
in which welding is done, otherwise
proper control of slag is difficult.
9.04
Power source problems
Description
Possible Cause
Remedy
1
The welding arc can not be
established.
A The Primary supply voltage has not A Switch on the primary
been switched on.
supply voltage.
B The welding power source switch is B Switch on the welding
switched off.
power source.
C Loose connections internally.
C Have an accredited BOSS
service agent repair the
connection.
2
Maximum output welding
current can not be achieved
with nominal Mains supply
voltage.
Defective control circuit.
Have an accredited BOSS
service agent inspect then
repair the welder.
Welding current
when welding.
Poor work lead connection to the work
piece.
Ensure that the work lead has a
positive electrical connection to
the work piece.
3
reduces
A Gas hose is cut.
B Gas passage contains impurities.
4
No gas flow when the torch
trigger switch is depressed.
C Gas regulator turned off.
A Replace gas hose.
B Disconnect gas hose from
the rear of power source
then raise gas pressure and
blow out impurities.
C Turn gas regulator on.
Table 17
Notice:
Can move the equipments that the power supply doesn't fixedly mean to link to work with gearing at the some
position.
- 22 BOSS ARC 140VRD、160VRD Operating Manual
10.0 PART LIST
- 23 BOSS ARC 140VRD、160VRD Operating Manual
- 24 BOSS ARC 140VRD、160VRD Operating Manual
Figure 6
QTY.
Sequence
Order No
Name
ARC 140VRD
ARC 160VRD
Sensor A Sensor B Sensor A Sensor B
1
3KITP000505020
BOARD,PCB,CONTROL (7.820.514-09)
1
3KITP000502002
BOARD,PCB,CONTROL
2
3KITP000106101
OUTPUT MMA160H
2
2
1
(7.820.514-10)
1
1
1
1
OUTPUT MMA160H(SENSOR)
3KITP000106000
2
OUTPUT MMA140
1
1
OUTPUT MMA140 (SENSOR)
2-1
3KITP000506011
BOARD,PCB,MOSFET (7.820.005B)
2-1
3KITP000106011
BOARD,PCB,MOSFET (7.820.016A)
2-2
3KITP000506021
BOARD,PCB,DIODE
(7.820.010A-02)
2-2
3KITP000506035
BOARD,PCB,DIODE
(7.820.010A-11)
2-2
3KITP000106022
BOARD,PCB,DIODE
(7.820.017-02)
2-2
1
1
1
1
1
1
1
1
BOARD,PCB,DIODE (7.820.017-09)
1
2-3
2HS7061062
HEATSINK LEFT-LOWER
1
1
2-4
2HS7061063
HEATSINK LEFT-UPPER-A
1
1
2-5
2HS7061064
HEATSINK LEFT-UPPER-B
1
1
2-6
2HS7061060
HEATSINK RIGHT-UPPER
1
1
2-7
2HS7061061
HEATSINK RIGHT-LOWER
1
1
2-3
2HS7061053
HEATSINK LEFT-LOWER
1
1
2-4
2HS7061054
HEATSINK LEFT-UPPER-A
1
1
2-5
2HS7061055
HEATSINK LEFT-UPPER-B
1
1
2-6
2HS7061051
HEATSINK RIGHT-UPPER
1
1
2-7
2HS7061052
HEATSINK RIGHT-LOWER
1
1
2-8
2FPPM8610005
BRACKET MOUNTING AL 200
1
1
2-8
2FPPM8610009
BRACKET MOUNTING AL 160
1
1
- 25 BOSS ARC 140VRD、160VRD Operating Manual
2-9
2-10
2-11
3KITP000106030
THERMOSTAT (Inside)
4VQK2SK2837
MOSFET 2837
1
1
1
12
12
16
16
12
12
16
16
2-12
4LZQ4X2X5
HOSE FERRITE 4*2*5
36
36
48
48
2-13
2FP8647002
INSULATOR II
16
16
20
20
2-14
2FP8647003
INSULATOR I
1
1
1
1
2-15
2FPBM8610016
BRACKET,HEATSINK MOUNTING
1
1
2-16
2FPBM8610017
BRACKET,HEATSINK MOUNTING
1
1
2-17
2FPBM8610021
BRACKET,HEATSINK MOUNTING I
2
2
2-18
2FPBM8610022
BRACKET,HEATSINK MOUNTING II
2
2
2-15
2FPBM8610000
BRACKET,HEATSINK MOUNTING
1
1
2-16
2FPBM8610001
BRACKET,HEATSINK MOUNTING
1
1
2-17
2FPBM8610019
BRACKET,HEATSINK MOUNTING I
2
2
2-18
2FPBM8610020
BRACKET,HEATSINK MOUNTING II
2
2
2-19
2FPPP8610117
BRACKET,MOSFET/DIODE (8.610.117)
9
9
16
16
2-20
2FPPP8610118
BRACKET,MOSFET/DIODE (8.610.118)
2
2
2-21
2FP7840003
INSULATOR,HEATSINK
1
1
2-21
2FP7840002
INSULATOR,HEATSINK
1
1
2FP7854011
SPACER,NYLON 凹 D5
8
8
8
8
4BFTDQ001D5
SPACER,NYLON 凸 D5
8
8
8
8
2FP7854015
SPACER,NYLON 凹 D4
2
2
2
2
4BFTDQ003D3BK
SPACER,NYLON 凸 D3
2
2
2
2
4ABKBPC3510
RECTIFIER
2
2
2
2
3
3KITP000107015
BOARD,PCB,POWER MMA (7.820.002F-01)
1
1
1
1
4
3KITP000509000
BOARD,PCB,RELAY-INPUT (7.820.000A)
1
1
8
3KITP002801010
BOARD,PCB,SENSOR (7.828.019A-02) (Inside)
9
3BB7725033
BUS BAR,POSITIVE
9
3BB7725032
BUS BAR,POSITIVE
10
3EER10002
COUPLING COIL
10
3EER10001
12
2LAU8803005
13
2LAN8808312
LABEL MANUFACTURERS RATING ARC 160VRD
13
2LAN8808309
LABEL MANUFACTURERS RATING ARC 140VRD
1
1
14
2LAM8800003
LABEL GROUND
1
16
2LAM8800001
LABEL VOLTAGE INPUT 240V 1PH
17
2FPB6123011
BASE 200=50
FP6.123.011
17
2FPB6123012
BASE 160=50
FP6.123.012
2-22
2-23
2-24
4V2HMM20FU020BC812 DIODE ULTRA FAST RECOVERY
1
19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
COUPLING COIL
1
1
LABEL (+ -)65*10
1
1
BRACKET ON/OFF SWITCH MOUNTING FP8.601.008
1
22
2FP7854025
INSULATOR WASHER (Inside)
4
4
4
4
23
2FP7854004
INSULATOR BULKHEAD FRONT
2
2
2
2
24
2FP7854008
INSULATOR BULKHEAD REAR
2
2
2
2
25
4SXJPG13R5
BUSHING,STRAIN RELIEF PG13.5
1
1
1
1
26
2GS50CC001FP
2
2
2
2
27
4KCD221BK
SWITCH
1
1
1
1
28
4KYZPN8D24
KNOB
1
1
1
1
RECEPTACLE,TWIST LOCK(FEMALE) POWER
- 26 BOSS ARC 140VRD、160VRD Operating Manual
30
4FANCA1238
FAN COVER
1
1
1
1
31
2FP8647000-1
CAP PROTECTION (Inside)
2
2
2
2
32
4JFT20X27
MOUNT NPRN JJ30
4
4
4
4
33
4FAN001SA1238
FAN
1
1
1
1
34
2PST8634001
INSULATOR FAN
1
1
1
1
36
481CC2KV103
CAPACITOR 3KV103
1
1
1
1
4V2FDLEDD5GN
LED GN
2
2
2
2
4V2FDLEDS01D5
LED BASE
2
2
2
2
4V2FDLEDD5RDGN
LED RD/GN
2
2
2
2
38
39
4V2FDLEDD5X7
LED BASE
2
2
2
2
40
4WTH1A2W1K
POTENTIONMETER 2W 1K
1
1
1
1
44
2FPPC8041109
PANEL CONTROL ARC 140VRD FP8.041.109
1
1
44
2FPPC8041124
PANEL CONTROL ARC 160VRD FP8.041.124
1
1
45
3KITP002406018
BOARD,PCB,VRD
1
1
46
2LAC8807272
OVERLAY CONTROL ARC 140VRD
46
2LAC8807273
OVERLAY CONTROL ARC 160VRD
1
1
47
2FPPT8040001Y
PANEL TOP FP8.040.001Y
1
1
47
2FPPT8040000Y
PANEL TOP FP8.040.000Y
1
1
48
4HDL00001
HANDLE
1
1
1
1
49
2LAW8805000
LABEL WARNING
1
1
1
1
50
2LAS8809040
LABEL BOSS
2
2
2
2
(7.825.018)
1
1
1
1
Table 18
11.0 Remark
11.1
11.2
11.3
11.4
11.5
11.6
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 sho uld electrify a time, a humidity
month of every two week should electrify use a time, by use own thermal row of tide.
- 27 BOSS ARC 140VRD、160VRD Operating Manual