BossWeld X Series Manual

AC/DC MULTI PROCESS
INVERTER WELDER
240V MANUAL
Thank you for choosing a BOSSWELD MST 200 X4 AC/DC Multi Process Inverter Welder
In this manual you will find instructions on how to set up your welder along with general welding information,
safety information and helpful tips. We encourage you to go online to our website for more tips and troubleshooting as well as many welding resources.
The BOSSWELD MST 200 X4 is the latest in IGBT multipurpose welder technology, this very portable power
source enables the user to complete high quality welds in both MIG - TIG - MMA/Stick electrode applications.
This welder is easy to set up, easy to use and will provide very smooth output.
We truly hope you enjoy using your welder!
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
& automotive repairs
METAL TYPES
Mild steel, stainless steel & aluminium
S
STICK
•
•
•
•
•
Easiest process to learn
Best choice for quick repairs
Slower than MIG welding
Forgiving in dirty/rusty environments
Not recommended for thin sheet metal welding
METAL TYPES
Mild steel, stainless steel & cast iron
T
TIG
•
•
•
•
•
Gives a better weld finish
Accurate heat control
Considered the most challenging process to learn
Good way to weld thin material
Argon gas is required
METAL TYPES
Mild steel, stainless steel & aluminium
2
P
P
Every effort has been made to ensure that this manual has been prepared accurately, however errors and omissions are excepted.
BOSSWELD is a trademark of Dynaweld Industrial Supplies Pty Ltd.
PLASMA CUTTING
CONTENTS
PAGE
WARRANTY4
BOX CONTENTS5
WARNINGS6
MACHINE CARE / SAFETY INSTRUCTIONS
7
WORK AREA SAFETY8
MAINTENANCE & DISPOSAL / GAS BOTTLE
9
FRONT & REAR PANEL LAYOUT
10
MACHINE CONTROLS PANEL & SIDE PANEL (INSIDE)
11
DUTY CYCLE12
MIG SYNERGIC SETUP13
MIG MANUAL SETUP (GAS)
16-17
MIG MANUAL SETUP (GASLESS)
18
MIG MANUAL SPOOL GUN SETUP (GAS)
20-22
MIG MANUAL SPOOL GUN SETUP (GASLESS)
23
BASIC MIG WELDING GUIDE
24-26
SETTING GUIDES FOR WELDING WITH MST 200X4
27
TIG SETUP28-31
LIFT ARC START AND HR ARC START
32
TUNGSTEN PREPARATION & GRINDING AND FOOT CONTROL OPTION
33
BASIC TIG WELDING GUIDE
34
AC / DC WELDING
34-35
PULSE TIG WELDING36
STICK AC / DC SETUP
37-38
GENERAL MMA WELDING GUIDE
39
SET UP OF WIRE SPOOL & WIRE FEED UNIT
40
MIG TORCH SETUP41
MACHINE DRIVE ROLLER SIZE GUIDE 41
MIG TORCH LINER INSTALLATION / REPLACEMENT
42
MIG TORCH AND CONSUMABLE CARE
43
LIST OF ERROR CODES
44
JOB PROGRAM DISPLAY INTRODUCTION
44
BZ 24 MIG TORCH PARTS BREAK DOWN
45
17 TIG TORCH PARTS BREAKDOWN
46
SPOOL GUN PARTS BREAKDOWN
47
HELPFUL INFORMATION & TROUBLE SHOOTING
48-51
3
WARRANTY
This warranty is in addition to the statutory warranty provided under Australian Consumer Law, but does not
include damage resulting from transport, misuse, neglect or if the product has been tampered with.
The product must be maintained as per this manual, and installed and used according to these instructions on
an appropriate power supply. The product must be used in accordance with industry standards and acceptable
practice.
This warranty covers the materials used to manufacture the machine and the workmanship used to produce the
item. This Warranty does not cover damage caused by:
1. Normal wear and tear due to usage
2. Misuse /abuse or Neglect of the item
3. Transport / handling breakages
4. Lack of maintenance, care and cleaning
5. Environmental factors, such as usage in temperatures exceeding 40 degrees, above 1000mt sea level, rain,
water, excessive damp, cold or humid conditions.
6. Improper setup or installation
7. Use on Incorrect voltage or non authorised electrical connections and plugs
8. Use of non standard parts
9. Repair, case opening, tampering with, modifications to any part of the item by non authorised BOSSWELD
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 to register for warranty on our website. www.bossweld.com.au/warranty
2. TIME PERIOD - 3 Years
A warranty claim must be made within 3 years from the date of purchase of this product. Any claim must include
proof of purchase.
3. HOW TO MAKE A CLAIM - NEED SOME HELP?
• Visit our website www.bossweld.com.au/troubleshooting for many helpful tips and guides to assist with the
setup and usage of your new machine. Still stuck….?
• Call the BOSSWELD Helpdesk on 1300 899 710 for over the phone assistance.
• If the machine is not operational then return the item to the place of purchase.
Note:
If this welders duty cycle is exceeded the welder will enter “thermal overload” which will
automatically stop the welding output in order to protect, both the user and the welder. You will know
the welder has gone into thermal overload when the overload error indicator light is illuminated.
The welder will then cool itself down, and once the overload error indicator light is no longer
illuminated, welding can then re-commence. Please note. Exceeding the machine’s duty cycle, cannot
be considered grounds for warranty or return.
4
BOSSWELD 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.
BOSSWELD MST 200 X4 AC/DC Multi Process Inverter Welder Box Contents
1.
BOSSWELD MST 200 X4 AC/DC Multi Process Inverter Welder
2.
3 metre BZ 24 Series MIG Torch
3.
4 metre 17 Series TIG Torch
4.
3 metre welding cable with electrode holder
5.
3 metre earth cable with earth clamp
6.
2 metre quick connect gas hose
7.
Dual stage Argon regulator
8.
Spanner
9.
0.8/0.9mm V groove drive rollers (Fitted)
0.8/0.9mm Knurled drive roller (Spare)
10.
Operating manual (not shown)
2
1
3
4
5
6
8
7
9
Note: Pictures may vary from your machine model
5
WARNING
The device and packaging material are not toys! Children must not be allowed to play with the machine and its
accessories. Plastic parts and packaging are choking risks for children.
• Open the packaging and remove the welder carefully.
• Check that the delivery is complete.
• If possible, store the packaging until the warranty period has expired.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
GLOVES AND PROTECTIVE CLOTHING
Use protective gloves and fire resistant protective clothing when welding.
Avoid exposing skin to ultraviolet rays produced by the arc.
WELDING HELMET
Under no circumstances should the welder be operated unless the operator is wearing a
welding helmet to protect the eyes and face. There is serious risk of eye damage if a helmet is
not used. The sparks and metal projectiles can cause serious damage to the eyes and face.
The light radiation produced by the arc can cause damage to eyesight, and burns to skin.
Never remove the welding helmet whilst welding.
SAFETY GLASSES
After welding use appropriate safety glasses when brushing, chipping or grinding the slag from
the weld.
OTHER PERSONS
Ensure that other persons are screened from the welding arc and are at least 15 metres away
from the work piece. Always ensure that the welding arc is screened from onlookers, or people
just passing by. Use screens if 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 electrical mains supply.
Do not leave hot material unattended after welding.
FUMES &GASES ARE DANGEROUS
Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding
produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of
the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding
fumes and gases.
• In confined or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
• Do not weld in locations near de-greasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can
give off toxic fumes when welded. Do not weld these materials unless the area is very well
ventilated, and or wearing an air supplied respirator.
6
MACHINE CARE / SAFETY
Keep the welding cables, earth clamp and electrode holder in good condition. Failure to do this can result in
poor welding quality, which could be dangerous in structural situations.
Prior to use, check for breakage of parts and any other conditions that may affect operation of the welder.
Any part of the welder that is damaged should be carefully checked to determine whether it will perform its
intended function whilst being safe for the operator. Any part that is damaged should be properly repaired, or
replaced by an authorised service centre.
IMPROPER USE
It is hazardous to use the welding machine for any work other than that for which it was designed e.g. do not
use welder for thawing pipes.
HANDLING
Ensure the handle is correctly fitted. As welding machines can be heavy, always use safe lifting practices when
lifting.
POSITION AND HANDLING
To reduce risk of the machine being unstable / danger of overturning, position the welding machine on a
horizontal surface that is able to support the machine weight. Operators MUST NOT BE ALLOWED to weld in
raised positions unless safety platforms are used.
SAFETY INSTRUCTIONS
WARNING
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 instructions before using this welder.
Persons who are not familiar with this user guide should not use this welder. Keep this booklet in a safe place
for future reference.
TRAINING
The operator should be properly trained to use the welding machine safely and should be informed about the
risks relating to arc welding procedures. This user guide does not attempt to cover welding technique. Training
should be sought from qualified / experienced personnel on this aspect, especially for any welds requiring a high
level of integrity for safety.
SERIOUS FIRE RISK
The welding process produces sparks, droplets of fused metal, metal projectiles and fumes.
This constitutes a serious fire risk. Ensure that the area in which welding will be undertaken is clear of all
inflammable materials. It is also advisable to have a fire extinguisher, and a welding blanket on hand to protect
work surfaces.
7
WORK AREA
Ensure a clear, well lit work area with unrestricted movement for the operator.
The work area should be well ventilated, as welding emits fumes which can be dangerous.
Always maintain easy access to the ON/OFF switch of the welder, and the electrical mains supply.
Do not expose the welder to rain and do not operate in damp or wet locations
Where welding must be undertaken in environments with increased risk of electric shock, confined spaces or in
the presence of flammable or explosive materials, it is important that the environment be evaluated in advance
by an “expert supervisor”. It is also recommended that welding in these circumstances be carried out in the
presence of persons trained to intervene in emergencies.
AVOID ELECTRICAL CONTACT
Use adequate electrical insulation with regard to the electrode, the work piece and any accessible earthed metal
parts in the vicinity. Avoid direct contact with the welding circuit. The no load voltage between the earth clamp
and the electrode can be dangerous under certain circumstances.
Note: For additional protection from electric shock. It is recommended that this welder be 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 outdoor use. Always keep
extension leads away from the welding zone, moisture and any hot materials.
WELDING SURFACES
Do not weld containers or pipes that hold, or have held, flammable liquids or combustible gases or pressure.
Do not weld on coated, painted or varnished surfaces as the coatings may ignite, or can give off dangerous
fumes.
WORK PIECE
When welding, the work piece will remain at high temperature for a relatively long period. The operator must not
touch the weld or the work piece unless wearing welding gloves. Always use pliers or tongs. Never touch the
welded material with bare hands until it has completely cooled.
VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES
Working with more than one welding machine on a single work piece, or on work pieces that are connected,
may generate a dangerous accumulation of no-load voltage between two different electrode holders or torches,
the value of which may reach double the allowed limit.
8
MAINTENANCE
WARNING
Before starting any cleaning, or maintenance procedures on the welding machine, make sure that it is switched
OFF and disconnected from the mains supply.
There are no user serviceable parts inside the welder. Refer to a qualified service personnel if any internal
maintenance is required. After use, wipe the welder down with a clean soft dry cloth.
Regular inspection of the supply cord is required and if damaged is suspected, it must be immediately replaced
by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard
STORAGE/ TRANSPORT
Store the welder and accessories out of children’s reach in a dry place. If possible store the welder in the
original packaging. The appliance must unconditionally be secured against falling or rolling over during
transport.
DISPOSAL
DISPOSING OF THE PACKAGING
Recycling packaging reduces the need for landfill and raw materials. Reuse of the recycled material
decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local
council authority for recycling advice.
DISPOSING OF THE WELDER
Welders that are no longer usable should not be disposed of with household waste but in an environmentally
friendly way. Please recycle where facilities exist. Check with your local council authority for recycling advice.
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 approximately 10-15 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the regulator, if the needle drops away towards zero there is a gas leak. Sometimes a gas leak can
be slow and to identify it will require leaving the gas pressure in the regulator and line for an extended
time period. In this situation it is recommended to open the cylinder valve, set the flow rate to 8-10 l/min,
close the cylinder valve and check after a minimum of 15 minutes. Ensuring adequate ventilation fore
small spaces.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with /
soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or fittings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your
machine. We recommend that you close the cylinder valve when the machine is not in use.
BOSSWELD, authorised representatives or agents of BOSSWELD will not be liable or responsible for the
loss of any gas.
9
FRONT PANEL
1.
2.
3.
4.
5.
6.
7.
Control Panel
Positive Output Connection Socket
MIG Torch Euro Connector
Control Socket
Polarity Switching Cable
TIG Torch Gas Connector
Negative Output Connection Socket
1
2
3
4
6
7
5
REAR PANEL
8.
9.
10.
11.
Power Switch
Input Power Cable
Cooling Fan
Gas Inlet Connector
8
9
10
10
11
CONTROL PANEL
1
4
2
5
3
6
7
8
9
1. Welding mode button:
MIG Synergic, MIG Manual, TIG Lift, TIG HF, Stick DC, Stick AC welding mode.
2. Trigger mode button: Direct select 2T or 4T trigger mode.
3. JOB button: Press for 3s to open JOB program and press for 1s to save parameters into
JOB number.
4. Synergic button: Press to select wire material, wire diameter and type of gas.
5. Gas check button: Manually purge to gas lines.
6. Manual wire feed button.
7. L parameter knob: Press to select parameters and rotate to adjust values, such as welding current. In function interface, rotate to select parameters.
8. Function button: Press to select parameters or enter the function interface.
9. R parameter knob: Press to select parameters and rotate to adjust values.
SIDE PANEL (DOOR OPEN)
A.
B.
C.
D.
E.
F.
G.
H.
Spool Hub
Spool Hub Nut
Wire Feed Tensioning Adjustment
Idle Roller / Wire Tensioning Arm
Wire Inlet
Drive Roller
A
Drive Roller Retainer Nut
B
Wire Guide Inlet Tube
C
D
E
F
G
H
11
DUTY CYCLE:
Special note:
If this welders duty cycle is exceeded the welder will enter “thermal overload” which will automatically
stop the welding output in order to protect, both the user and the welder. You will know the welder has
gone into thermal overload when the overload error signal show on screen.
The welder should not be welding for 10~15 minutes to cool down with the fan running. When operating
the machine again, the welding output current or the duty cycle should be reduced. Please note.
Exceeding the machine’s duty cycle, cannot be considered grounds for warranty or return.
The term duty cycle indicates the percentage welding time available at the output current for each 10 min period
over 4 hours, The specification plate on the machine list three given ratings at a given current and voltage.
NOTE MIG SETTINGS SHOW BELOW : Amps refer to the Current setting
10%
60%
100%
200 - Amps
85-Amps
65-Amps
24.0 Volts
18.3 Volts
17.3 Volts
For example this means when the machine is set at is highest current of 200 Amps it can weld for 1 minute in a
Ten minute period. The power source is protected by a built in temperature protection device, This will activate if
the machine is operated in excess of its amperage and duty cycle rating.
Duty Cycle
Amperage
/ Current
Voltage
Amperage and Voltage display
12
MIG SYNERGIC SETUP
11 & 12. 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
10. Select MIG Synergic mode
4. Connect polarity switching
cable to the
terminal
4. Connect MIG Torch to the
Euro Connection terminal
NOTE: Ensure connector
nut is tighten firmly
5. Connect earth clamp
to the
terminal
IMPORTANT! - We strongly recommend that you
check for gas leakage prior to operation of your
machine. We recommend that you close the cylinder
valve when the machine is not in use. BOSSWELD
authorised representatives or agents of BOSSWELD
will not be liable or responsible for the loss of any gas.
OFF
1
2
Plug the machine 10Amp input power lead
into the wall socket, ensuring that the power
switch on the machine is in the OFF position.
3
Open wire feed side panel and install GAS
wire into machine ensuring the drive roller is
matched to the wire size and type. Refer to
Machine Drive Roller Size Guide on page 41
Note: Wire to roll from under spool into the
wire guide inlet tube
4
Set up the wire feed unit as per section
“Set up Wire Feed Unit”. Ref page 40
Install Euro connect MIG torch over the
protruding wire, line up and screw the Euro
connector nut up firmly. Ensure the polarity
switching cable is plug into positive output
connection socket for gas welding.
SETTING MACHINE POLARITY
DCEN - GASLESS
Drive roller
size (mm)
DCEP - GAS
Roller Groove
V Groove - Mild Steel
U Groove - Aluminium
V-knurled - Gasless Wire
Note: Pictures may vary from your machine model
13
MIG SYNERGIC SETUP CONTINUE
5
Fit the Earth lead Dinse Plug to the negative
terminal for gas welding and then connect
earth clamp to the work piece ensuring that
the clamp makes good contact with bare metal.
9
Re install tip and nozzle to torch and
trim wire to the end of the nozzle.
ON
Press Synergic button and adjust knob to
6
Switch the machine ON using the mains
power switch. Wait a few seconds whilst
the machine powers up.
10 select wire material, wire diameter & type
of gas. Press knob to confirm.
Wire Material
Wire Diameter
Iron
Fe
Flux Cored Iron
Flux.c.w Fe Ø 0.8 / 0.9 / 1.0mm
Ø 0.8 / 0.9 / 1.0mm
98%Ar+2%CO2
Aluminium
Ø 0.8 / 0.9 / 1.0mm
Ar 100%
Al
Ar 100%
Ar 100%
98%Ar+2%CO2
CO2
14
Remove nozzle and tip from torch and press
wire feed button, this will feed the wire
through the torch. Release button when wire
appears at the end of the torch.
80%Ar+20%CO2
8
Press Menu button and adjust knob to select
MIG Synergic then press knob to confirm.
CO2
Stainless Steel Ss
Copper-Silicon Cusi3
7
Type of gas
80%Ar+20%CO2
Ø 0.6 / 0.8 / 0.9 / 1.0mm
CO2
Follow Synergic control instruction to get the right
type of gas to set up for this machine.
11
Fit gas regulator to the gas bottle and install
gas hose to the gas inlet on the back panel
of welder.
Note: Pictures may vary from your machine model
MIG SYNERGIC SETUP CONTINUE
12
13
Turn on regulator and set gas flow to
between 10-15 L/min depending on your
welding environment.
15
Machine is ready to weld at optimum
setting. If the welder is running too hot,
adjusting the left knob back a little will also
adjust the wire feed speed and Amps, all in
‘Synergy’ with each other.
16
Rotate right knob to trim the welding voltage.
Press 2T/4T button to select 2T or 4T mode.
2T Mode. Press the gun/torch trigger to
weld and release to stop. 4T Mode. Press
and release the gun/torch trigger to start,
weld without holding the trigger on and stop
by pressing and releasing the trigger again.
Press 2 times on the right knob for ∆U
Delta Voltage; it’s show the difference of
the preset voltage programmed, rotate to
adjust if necessary.
Press 1 time on the right knob for
Inductance; it works by creating a magnetic
field which opposes the welding current in
the short circuit thereby slowing the rate
of rise. If the inductance is increased it will
cause an increase in arc time and reduction
in the dip frequency, this will help reduce
spatter.
Ref MIG Welding Setting Guide on page
24-27
14
To adjust functions, press parameter button,
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Function
Settings
Adjustments
U Delta Voltage
-4 ~ 4
Inductance
0 ~ 10
∆
Setting
1 Trigger
2T or 4T
2 Burnback
0 ~ 10
3 Pre-Flow
0.1s ~ 5s
4 Post Flow
0.1s ~ 10s
5 Slow Feed
0 ~ 10
Selection for 2T and 4T.
Selection for the amount
of wire to ‘burn back’ after
release the torch trigger.
Selection for gas flow time
prior to the arc starting.
Selection for gas flow time
after the arc finishes.
Selection for wire feed
speed before arc start
Note:
It is advisable to run a few test welds using
scrap or offcut materials, in order to tune
the machine to the correct settings prior to
welding the job.
Note: Pictures may vary from your machine model
15
MIG MANUAL SETUP (GAS)
6 & 7. 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
9. Select MIG Manual mode
4. Connect polarity switching
cable to the
terminal
4. Connect MIG Torch to the
Euro Connection terminal
NOTE: Ensure connector
nut is tighten firmly
5. Connect earth clamp
to the
terminal
IMPORTANT! - We strongly recommend that you
check for gas leakage prior to operation of your
machine. We recommend that you close the cylinder
valve when the machine is not in use. BOSSWELD
authorised representatives or agents of BOSSWELD
will not be liable or responsible for the loss of any gas.
OFF
1
2
Plug the machine 10Amp input power lead
into the wall socket, ensuring that the power
switch on the machine is in the OFF position.
3
Open wire feed side panel and install GAS
wire into machine ensuring the drive roller is
matched to the wire size and type. Refer to
Machine Drive Roller Size Guide on page 41
Note: Wire to roll from under spool into the
wire guide inlet tube
4
Set up the wire feed unit as per section
“Set up Wire Feed Unit”. Ref page 40
Install Euro connect MIG torch over the
protruding wire, line up and screw the Euro
connector nut up firmly. Ensure the polarity
switching cable is plug into positive output
connection socket for gas welding.
SETTING MACHINE POLARITY
DCEN - GASLESS
16
Drive roller
size (mm)
DCEP - GAS
Roller Groove
V Groove - Mild Steel
U Groove - Aluminium
V-knurled - Gasless Wire
Note: Pictures may vary from your machine model
MIG MANUAL SETUP (GAS) CONTINUE
5
Fit the Earth lead Dinse Plug to the negative
terminal for gas welding and then connect
earth clamp to the work piece ensuring that
the clamp makes good contact with bare metal.
9
Press Menu button and adjust knob to select
MIG Manual then press knob to confirm.
Remove nozzle and tip from torch and press
6
Fit gas regulator to the gas bottle and install
gas hose to the gas inlet on the back panel
of welder.
10 wire feed button, this will feed the wire
through the torch. Release button when wire
appears at the end of the torch.
11
7
Turn on regulator and set gas flow to
between 10-15 L/min depending on your
welding environment.
Re install tip and nozzle to torch and
trim wire to the end of the nozzle.
ON
12
8
Switch the machine ON using the mains
power switch. Wait a few seconds whilst
the machine powers up.
Note: Pictures may vary from your machine model
Press 2T/4T button to select 2T or 4T mode.
2T Mode. Press the gun/torch trigger to
weld and release to stop. 4T Mode. Press
and release the gun/torch trigger to start,
weld without holding the trigger on and stop
by pressing and releasing the trigger again.
17
MIG MANUAL SETUP (GAS) CONTINUE
13
To adjust functions, press parameter button,
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Function
Setting
1 Trigger
2T or 4T
2 Burnback
0 ~ 10
3 Pre-Flow
0.1s ~ 5s
4 Post Flow
0.1s ~ 10s
5 Slow Feed
0 ~ 10
Selection for 2T and 4T.
Selection for the amount
of wire to ‘burn back’ after
release the torch trigger.
Selection for gas flow time
prior to the arc starting.
Selection for gas flow time
after the arc finishes.
Selection for wire feed
speed when welding
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.
14
Rotate left knob to adjust wire feeding speed.
Rotate right knob to adjust welding voltage.
Press 1 time on the right knob for
Inductance; it works by creating a magnetic
field which opposes the welding current in
the short circuit thereby slowing the rate
of rise. If the inductance is increased it will
cause an increase in arc time and reduction
in the dip frequency, this will help reduce
spatter.
Function
m/min
U
Setting
Wire Feeding Speed
1.5 ~ 18.0
Welding Voltage
10.0 ~ 27.0
Inductance
0 ~ 10
Ref MIG Welding Setting Guide on page
24-27
MIG MANUAL SET UP (GASLESS)
9.Select MIG
Manual mode
6. Connect earth Clamp
to the
terminal
4. Connect MIG Torch to the
Euro Connection terminal
NOTE: Ensure connector
nut is tighten firmly
18
5. Connect polarity
switching cable to
the
terminal
Note: Pictures may vary from your machine model
MIG MANUAL SETUP (GASLESS) CONTINUE
OFF
1
Plug the machine 10Amp input power lead into
the wall socket, ensuring that the power
switch on the machine is in the OFF position.
5
Ensure the polarity switching cable is
plug into negative output connection
socket for gasless welding
SETTING MACHINE POLARITY
DCEN - GASLESS
2
DCEP - GAS
Open wire feed side panel & install GASLESS
wire into machine ensuring the drive roller is
matched to the wire size and type. Refer to
Machine Drive Roller Size Guide on page 41
Note: Wire to roll from under spool into the
wire guide inlet tube
Drive roller
size (mm)
Roller Groove
V Groove - Mild Steel
U Groove - Aluminium
V-knurled - Gasless Wire
6
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.
ON
3
Set up the wire feed unit as per section
“Set up Wire Feed Unit”. Ref page 40
Install Euro connect MIG torch over the
4 protruding wire, line up the spring connectors
and screw the Euro connector nut up firmly.
7
Switch the machine ON using the mains
power switch. Wait a few seconds whilst
the machine powers up.
8
Continue from MIG manual GAS set up
page 17; step 9 to 14.
Note:
It is advisable to run a few test welds using scrap
or offcut materials, in order to tune the machine
to the correct settings prior to welding the job.
Note: Pictures may vary from your machine model
19
NOTE: SPOOL GUN IS NOT SUPPLIED WITH MACHINE - SEE PAGE 47 FOR TORCH OPTIONS
MIG MANUAL SPOOL GUN SETUP
5 & 6. 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
14.Select MIG Manual mode
3. Connect polarity switching
cable to the
terminal
2. Connect Spool Gun to
the Euro Connection terminal
NOTE: Ensure connector
nut is tighten firmly
3. Connect earth Clamp
to the
terminal
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine.
We recommend that you close the cylinder valve when the machine is not in use. BOSSWELD authorised
representatives or agents of BOSSWELD will not be liable or responsible for the loss of any gas.
OFF
1
Plug the machine 10Amp input power lead into
the wall socket, ensuring that the power
switch on the machine is in the OFF position.
3
Fit the earth clamp to negative terminal and
ensure the polarity switching cable is connect
to positive output connection socket
SETTING MACHINE POLARITY
DCEN - GASLESS
20
2
DCEP - GAS
Install the Spool Gun to the machine by
connecting Euro Connector and the
Control Socket and screw the nut up firmly
Note: Pictures may vary from your machine model
MIG MANUAL SPOOL GUN SETUP CONTINUED
4
Connect earth clamp to the work piece
ensuring that the clamp makes good
contact with bare metal.
8
Remove the spool cover and lift wire drive
cover
TOP
VIEW
5
Fit gas regulator to the gas bottle and install
gas hose to the gas inlet on the back panel
of welder.
6
Turn on regulator and set gas flow to
between 10-15 L/min depending on your
welding environment.
9
Release the wire tensioning arm, and
check the correct drive roller size matches
the wire being used
10
Feed the wire over the drive roller and into
the inlet guide, make sure you hold the
spool to stop it unraveling.
TOP
VIEW
7
Open wire cover panel by loosening the
retaining nut and removing the cover
Re-latch the tensioning arm, making sure
11 you still hold the spool to stop it unraveling.
Screw in to increase tension.
Note: Pictures may vary from your machine model
21
MIG MANUAL SPOOL GUN SETUP CONTINUED
Replace the spool cover and close the wire
12 drive cover
16
Re install tip and nozzle to torch and trim
wire to the end of the nozzle.
ON
13
Switch the machine ON using the mains
power switch. Wait a few seconds whilst
the machine powers up.
17
Press 2T/4T button to select 2T or 4T mode.
2T Mode. Press the gun/torch trigger to
weld and release to stop. 4T Mode. Press
and release the gun/torch trigger to start,
weld without holding the trigger on and stop
by pressing and releasing the trigger again.
Press Menu button and adjust knob to select
14 MIG Manual then press knob to confirm
18
To adjust functions, press parameter button,
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Turn the spool gun selection ON.
Function
15
22
Remove nozzle and tip from torch and
press wire feed button, this will feed the
wire through the torch. Release trigger
when wire appears at the end of the torch.
Note: Pictures may vary from your machine model
Setting
1 Trigger
2T or 4T
2 Burnback
0 ~ 10
3 Pre-Flow
0.1s ~ 5s
4 Post Flow
0.1s ~ 10s
5 Slow Feed
0 ~ 10
6 Spool Gun
ON or OFF
Selection for 2T and 4T.
Selection for the amount
of wire to ‘burn back’ after
release the torch trigger.
Selection for gas flow time
prior to the arc starting.
Selection for gas flow time
after the arc finishes.
Selection for wire feed
speed when welding
Switch for Spool Gun
MIG MANUAL SPOOL GUN SETUP CONTINUED
Ref MIG Welding Setting Guide on page 24-27
Function
m/min
U
Wire Feeding Speed
1.5 ~ 16.0
Welding Voltage
10.0 ~ 27.0
Inductance
19
Setting
0 ~ 10
Rotate left knob to adjust wire feeding speed.
Rotate right knob to adjust welding voltage.
Press 1 time on the right knob for
Inductance; it works by creating a magnetic
field which opposes the welding current in
the short circuit thereby slowing the rate
of rise. If the inductance is increased it will
cause an increase in arc time and reduction
in the dip frequency, this will help reduce
spatter.
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.
MIG MANUAL SPOOL GUN SET UP (GASLESS)
OFF
1
2
Plug the machine 10Amp input power lead into
the wall socket, ensuring that the power
switch on the machine is in the OFF position.
3
Ensure the polarity switching cable is
plug into negative output connection
socket for gasless welding
4
Install the Spool Gun to the machine by
connecting Euro Connector and the
Control Socket and screw the nut up firmly
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.
SETTING MACHINE POLARITY
DCEN - GASLESS
DCEP - GAS
5
Continue from MIG manual spool gun set
up page 21; step 7 to 19.
Note: Pictures may vary from your machine model
23
BASIC MIG WELDING GUIDE
The welding power supply has two control settings that have to balance. These are voltage control switches
and the wire speed control. The welding amperage is determined by the voltage settings, the wire diameter,
gas selection and the wire feed speed. The amperage will increase with higher voltage selection on the
machine and higher wire feed speed. This is typically used for welding thick sections of steel. When welding
thin sections of steel, a lower voltage selection and lower wire feed speed is required.
• When changing to a different wire diameter different control settings are required. A thinner wire needs
more wire speed to achieve the same current level.
• A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to
suit the wire diameter and thickness of the material being welded.
• 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.
POSITION OF MIG GUN
The angle of MIG gun to the weld has an effect on the width of the weld run.
Push
10˚
Perpendicular
Wire Direction
ahead of bead
10˚
Drag
Wire Direction
ahead of bead
Direction Of Welding
Push Technique
24
Gun Perpendicular
Drag (Pull) Technique
BASIC MIG WELDING GUIDE - CONTINUE
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 when welding with
gas shielded wire. An increased distance of 5mm to 10mm is required when welding with Gasless wire. This
distance will vary depending on the type of joint that is being weld. .
Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run. Welding
thin steel will have a faster travel speed than welding thick steel.
Wire Size Selection
The choice of wire size in conjunction with shielding gas used depends on:
• Thickness of the metal to be welded.
• Type of joint configuration
• 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 wire.
• Location of welding
Metal inert gas (MIG) welding is an attractive alternative to MMA (stick welding), offering high deposition
rates and high productivity.
PROCESS CHARACTERISTICS
MIG welding is a versatile technique suitable for both thin sheet and thick section components. An arc is
struck between the end of a wire electrode and the workpiece, melting both of them to form a weld pool.
The wire serves as both heat source (via the arc at the wire tip) and filler metal for the joint. The wire is fed
through a copper contact tube (contact tip) which conducts welding current into the wire. The weld pool is
protected from the surrounding atmosphere by a shielding gas fed through a nozzle surrounding the wire.
Shielding gas selection depends on the material 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 wire is continuously fed.
Manual MIG welding is often referred as a semi-automatic process, as the wire feed rate and arc length are
controlled by the power source, but the travel speed and wire position are under manual control. The process
can also be mechanised when all the process parameters are not directly controlled by a welder, but might
still require manual adjustment during welding. When no manual intervention is needed during welding, the
process can be referred to as automatic. The process usually operates with the wire positively charged and
connected to a power source delivering a constant voltage. Selection of wire diameter (usually between 0.6
and 1.6mm) and wire feed speed determine the welding current, as the burn-off rate of the wire will form an
equilibrium with the feed speed.
25
BASIC MIG WELDING GUIDE - CONTINUE
SHIELDING GAS
In addition to general shielding of the arc and the weld pool, the shielding gas performs a number of
important functions:
• forms the arc plasma
• stabilises the arc roots on the material surface
• ensures smooth transfer of molten droplets from the wire to the weld pool
The shielding gas will have a substantial effect on the stability of the arc and metal transfer and the
behaviour of the weld pool, in particular, its penetration. General purpose shielding gases for MIG welding
are mixtures of argon, oxygen and CO2, and special gas mixtures may contain helium.
The gases which are 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. As CO2 cannot be used in the open arc (pulsed or spray transfer) modes
due to high back-plasma forces, argon based gases containing oxygen or CO2 are normally employed.
WELDING GAS SELECTION CHART GUIDE
M
MIG
MIG WELDING
ARGON
Ar-CO2-O2
MILD STEEL
X
√
STAINLESS STEEL
X
√
LOW ALLOY STEEL
X
√
GALVINISED STEEL
X
√
ALUMINIUM
√
X
TRIGGER
SHROUD
CONTACT TIP
WELDING WIRE
SHIELDING GAS
MOLTEN WELD METAL
DROPLETS
ARC
WORK PIECE
26
WORK PIECE
SETTING GUIDE FOR WELDING WITH MST 200X4
Steel
Material
Thickness
DC (+)
Solid
80% Argon 20% CO2
Ø 0.6mm
0.8mm
1.0mm
1.2mm
1.6mm
2.0mm
3.0mm
5.0mm
6.0mm
8.0mm
Ø 0.8mm
Ø 0.9mm
m/min
V
m/min
V
m/min
5.5
6.7
8.1
9.5
11.0
14.0
14.0
14.8
15.3
17.0
18.5
20.0
3.0
3.6
4.4
5.1
5.5
6.8
10.0
12.5
15.3
14.5
15.0
15.6
16.3
16.8
18.0
19.5
20.5
23.8
2.9
3.7
4.3
4.9
6.8
9.5
10.8
12.8
-
100% CO2
Ø 1.0mm
V
m/min
14.0
14.8
14.5
15.8
18.4
20.5
24.5
Stainless
m/min
14.0
14.8
14.5
15.8
18.4
20.5
24.5
3.4
3.8
4.8
6.0
6.8
8.3
14.0
15.8
Material
Thickness
m/min
m/min
16.0
16.5
17.3
18.1
18.8
20.4
23.4
24.5
3.5
4.1
4.6
5.1
6.3
9.2
11.1
Steel
14.2
15.7
16.7
17.4
18.6
V
4.8
5.8
7.0
9.7
m/min
-
V
15.1
16.0
17.2
18.8
17.0
17.7
18.6
19.0
19.8
22.2
24.1
DC (-)
Ø 1.0mm
-
m/min
4.1
5.0
5.9
8.2
12.6
14.2
m/min
V
Ø 0.9mm
m/min
V
3.0
3.4
3.7
14.5
6.7
8.3
10.4
16.5
17.0
17.2
17.9
20.8
23.5
26.5
DC (+)
Ø 1.0mm
m/min
V
100% Argon
Ø 1.0mm
m/min
V
Ø 1.0mm
m/min
V
-
15.1
16.1
16.7
18.3
22.2
23.7
-
Ø 0.8mm
V
Aluminium
No Gas for Inner Shield Wires
m/min
V
-
98% Argon 2% CO2
Ø 0.9mm
Ø 1.0mm
-
Cored
-
-
V
Solid
V
4.6
6.3
8.3
9.4
12.5
Ø 0.9mm
-
DC (+)
Ø 0.8mm
0.8mm
1.0mm
1.2mm
1.6mm
2.0mm
3.0mm
5.0mm
6.0mm
8.0mm
V
-
14.3
14.8
16.4
16.8
19.0
21.8
22.4
26.8
Ø 0.8mm
5.1
6.0
7.4
8.7
12.0
15.0 5.0 17.4
15.3 5.8 17.9 4.8 17.3
7.0 16.4
17.3 7.0 18.6 5.3 17.5 7.0 17.0 9.0 17.6
19.5 8.1 19.2 6.1 18.0 8.3 17.4 11.0 18.4
21.5 10.7 21.9 7.6 19.0 10.3 19.3 15.0 19.8
14.2 24.4 11.2 22.4 13.3 23.0 16.0 21.0
12.5 23.2
-
27
TIG SET UP
6 & 7. 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
10.Select TIG LIFT
OR HF Start mode
2. Connect TIG Torch
Control Socket and
screw the nut up firmly
5. Connect earth Clamp
to the
terminal
2. Connect the Gas hose
to the Gas Output
2. Connect TIG Torch
to the
terminal
OFF
1
2
28
Plug the machine 10Amp input power lead into
the wall socket, ensuring that the power
switch on the machine is in the OFF position.
Install the TIG Torch to the machine by
connecting the Dinse Connector to the
Negative Output Connection Socket, the
Gas hose to the Gas Output and the TIG
Torch Control Socket and screw the nut up
firmly.
3
Set up the TIG torch. Ensure collect body,
collet with back cap are screw in firmly.
4
Place the Tungsten Electrode into the torch
head then screw in alumina cap.
Note: Pictures may vary from your machine model
TIG SET UP - CONTINUED
ON
5
Fit the Earth lead Dinse Plug to the positive
terminal for gas welding and then connect
earth clamp to the work piece ensuring that
the clamp makes good contact with bare metal.
6
Fit gas regulator to the gas bottle and install
gas hose to the gas inlet on the back panel
of welder.
7
Turn on regulator and set gas flow to
between 10-15 L/min depending on your
welding environment.
13
9
10
IMPORTANT! - We strongly recommend that you
check for gas leakage prior to operation of your
machine. We recommend that you close the
cylinder valve when the machine is not in use.
BOSSWELD authorised representatives or agents
of BOSSWELD will not be liable or responsible for
the loss of any gas.
Switch the machine ON using the mains
power switch. Wait a few seconds whilst
the machine powers up.
Press 2T/4T button to select 2T or 4T mode.
2T Mode. Press the gun/torch trigger to
weld and release to stop. 4T Mode. Press
and release the gun/torch trigger to start,
weld without holding the trigger on and stop
by pressing and releasing the trigger again.
Press MENU and adjust knob to select TIG
Lift or HF mode then press knob to confirm.
TIG Lift is a method of starting the arc
when TIG welding that enables the operator
to touch the tungsten to the work piece,
lift it off the work piece, and then have full
welding current begin flowing.
TIG HF (high frequency ignition) allows the
operator to position the tungsten electrode
near the job, and simply press the torch
trigger to start the arc.
Ref Lift Arc Start and HF Arc Start Guide on
page 32
Note: Pictures may vary from your machine model
29
TIG SET UP - CONTINUED
For NO Pulse Welding
11A To adjust functions, press parameter button,
11B
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Ref Pulse TIG Welding Guide on page 36
Function
Selection for Pulse,
No Pulse or Spot
3 Trigger
2T or 4T
Selection for 2T and 4T
4 Pre-Flow
0.0s ~ 2.0s
1 AC/DC
2
5
Pulse
Weld
Pre
Current
6 Up Slope
7
Welding
Current
8
Down
Slope
9
Post
Current
10 Post Flow
DC
DC
AC
AC
AC
AC
AC
AC
Direct current TIG (DC) welding is when the current
flows in one direction only. Compared with AC
(Alternating Current) TIG welding the current once
flowing will not go to zero until welding has ended. ​
DC is used for TIG welding Mild Steel/Stainless
material and AC would be used for welding Aluminium.
30
Ref Pulse TIG Welding Guide on page 36
Selection and DC output
or AC wave output
Selection for gas flow
time prior to the arc
starting
Selection for the amount
10A ~ 200A of amps required at the
start of the weld
Selection for the transition
0.0s ~ 10.0s time from Start Amperage
to Peak Amperage
Selection for the current
that flows through a
10A ~ 200A
circuit while a weld is
being made.
Selection for the transition
time from Peak Amperage
0s ~ 10s
to Finish Amperage
Selection for the amount
10A ~ 200A of amps required at the
end of the weld
Selection for gas flow
0s ~ 10s
time after the arc finishes
Ref AC / DC Welding Guide on page 34-35
Pulse TIG welding is most commonly used
to weld thin sections of stainless steel,
non-ferrous metals such as aluminum,
magnesium and copper alloys. It is
comparatively more complex in functions.
To adjust functions, press parameter button,
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Setting
AC: Sine,
Square &
Triangle
DC
On or off
(TIG HF: Spot)
For Pulse Welding
Function
1 AC/DC
2
Pulse
Weld
3 Trigger
Setting
AC: Sine,
Square &
Triangle
DC
On or off
(TIG HF: Spot)
Selection and DC output
or AC wave output
2T or 4T
Selection for 2T and 4T
DC
AC
AC
AC
Selection for Pulse,
No Pulse or Spot
Selection for gas flow
time prior to the arc
starting
Selection for the amount
Pre
5
10A ~ 200A of amps required at the
Current
start of the weld
Selection for the transition
6 Up Slope 0.0s ~ 10.0s time from Start Amperage
to Peak Amperage
Selection for the Maximum
Peak
7
10A ~ 200A Welding Amperage
Current
required during welding
Selection for the Base
Base
8
10A ~ 200A Welding Amperage required
Current
during welding
Selection for the frequency
with which the welding
Pulse
0.5Hz ~
9
amperage goes from
Frequency 999Hz
peak amperage to a basic
current in a second
Selection for the percentage
10 Duty Cycle 5% ~ 95%
of time for safely operate
Selection for the transition
Down
11
time from Peak Amperage
0s ~ 10s
Slope
to Finish Amperage
Selection for the amount
Post
12
10A ~ 200A of amps required at the
Current
end of the weld
Selection for gas flow
13 Post Flow 0s ~ 10s
time after the arc finishes
4 Pre-Flow
0.0s ~ 2.0s
TIG SET UP - CONTINUED
11C
For Spot Welding
Spot welding is quick and easy and creates
a strong join. It doesn’t use any flux or filler
metal, so there is no need to grind excess
slag when finished, and there is no dangerous
open flame.
12A
For DC Welding
Rotate left knob to adjust welding current.
Rotate right knob to adjust the welding voltage.
Ref AC / DC Welding Guide on page 34-35
It can only create localized joins and can be
challenging to join oddly shaped pieces of
metal.
To adjust functions, press parameter button,
rotate left knob for function selection and
rotate right knob for adjustment then press
parameter button again for confirmation.
Function
1 AC/DC
2
Pulse
Weld
3 Pre-Flow
Setting
AC: Sine,
Square &
Triangle
DC
On or off
(TIG HF: Spot)
0.1s ~ 2.0s
Welding
Current
10A ~ 200A
5 Time on
0.2s ~ 1.0s
6 Time off
0s ~ 10s
4
7 Post Flow 0.1s ~ 10s
DC
AC
AC
AC
Selection and DC output or
AC wave output
Selection for Pulse,
No Pulse or Spot
Selection for gas flow time
prior to the arc starting
Selection for the current
that flows through a
circuit while a weld is
being made.
The amount of time
welding, to ensure welds
are the same size and or
length.
The time between welds,
to allow to move the torch
position to new location /
stitch weld.
Selection for gas flow time
after the arc finishes
For AC Welding
12B Rotate left knob to adjust welding current.
Rotate right knob to adjust the welding voltage.
Press one time on the right knob for
AC Balance; this control allows the
operator to adjust the balance between the
penetration (EN) and cleaning action (EP)
portions of the cycle.
It produces a greater cleaning action to
remove heavy oxidation and minimizes
penetration, which may help prevent burnthrough on thin materials. Reducing the
EN cycle, however, decreases tungsten
electrode life and increases balling action
because more heat is being directed into
the electrode. This creates a large ball at
the end of the tungsten and causes the arc
to lose stability, making it hard to direct the
arc weld puddle.
Press two times on the right knob for
AC Frequency; it controls the width of
the arc cone. Increasing the AC frequency
provides a more focused arc with increased
directional control. Decreasing the AC
frequency softens the arc and broadens the
weld puddle for a wider weld band.
Ref AC / DC Welding Guide on page 34-35
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.
~f
Function
Setting
AC Balance
-5 ~ 5
AC Frequency
50 ~ 250Hz
31
LIFT ARC START
1
2
Lay the outside edge of the Gas Cup on
the work piece with the Tungsten Electrode
1- 2mm from the work piece.
Press the button on the TIG torch
3
With a small movement rotate the Gas Cup
forward so that the Tungsten Electrode
touches the work piece.
4
Now rotate the Gas Cup in the reverse
direction to lift the Tungsten electrode from
the work piece to create the arc.
3
The Arc will start forming an arc between
the tungsten tip and the work piece
HF ARC START
1
32
2
Lay the outside edge of the Gas Cup on the
work piece with the Tungsten Electrode
1- 2mm from the work piece.
Press the button on the TIG torch
Note: Pictures may vary from your machine model
TUNGSTEN PREPARATION & GRINDING
Caution: Grinding can create a hazard as the exposed tungsten/thoria area is greatly increased and fine
particles of dust are released into the atmosphere. It is recommended that a dedicated grindstone with local
dust extraction is used, and a simple filter mask is worn. If the grinding wheel is not
fitted with a protective viewing screen, eye protection must be worn.
CORRECT PREPERATION - STABLE ARC
INCORRECT PREPERATION - STABLE ARC
STRAIGHT GROUND
RADIAL GROUND
STABLE ARC
ARC WANDER
FLAT TIP
GRINDING WHEEL
POINTED TIP
GRINDING WHEEL
Note: Do not use wheel for other jobs or tugsten can become contaminated and cause lower weld quality
FOOT CONTROL - OPTIONS
Bossweld Foot Control 3mt
Part No: 660201
GAS LENS
TUNGSTEN ELECTRODE
FILLER WIRE
3 metre cord Ideal for bench work Parent-Child relationship between the welder and foot controller.
This means if you set the welder to 120 Amps, the foot controller range will be between min and 120 Amps.
WORK PIECE
WORK PIECE
Bossweld 12-9 Plug Adaptor
Part No: 95.PA1209
This plug adaptor must be used with the
Bossweld foot controller (P/N-660201),
when used with the MST 200X4.
The adaptor also allows the Bossweld TIG torches
with 12 pin plugs to be used with the MST 200X4.
33
BASIC TIG WELDING GUIDE
FLUX COATING
ROD
PROCESS CHARACTERISTICS
In the TIG process the arc is formed between a pointed tungsten electrode and the workpiece in an inert
ARC
atmosphere of argon. The small intense arc provided by the pointed electrode is ideal for high quality and
precision welding. Because the electrode is not consumed during welding, the welder does not have to
balance the heat input from the arc as the metal is deposited from the melting electrode. When filler metal is
required, it must be added separately to the weldpool.
WORK PIECE
WORK PIECE
POWER SOURCE
TIG must be operated with a constant current power source. A constant current power source is essential
to avoid excessively high currents being drawn when the electrode is short-circuited onto the workpiece
surface. This could happen either deliberately during arc starting or inadvertently during welding. If, as in
MIG welding, a flat characteristic power source is used, any contact with the workpiece surface would
CORRECT PREPERATION
STABLE
INCORRECT
damage the electrode tip or fuse the electrode to the workpiece
surface. -In
DC,ARC
because arc
heat is PREPERATION - STABLE ARC
distributed approximately one- third at the cathode (negative)
andGROUND
two-thirds at the anode (positive),
the
STRAIGHT
RADIAL GROUND
electrode is always negative polarity to prevent overheating and melting. However,
the
alternative
power
STABLE ARC
ARC WANDER
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 contamination.
FLAT TIP
POINTED TIP
APPLICATIONS
GRINDING
WHEEL
WHEEL welding,
TIG is applied in all industrial sectors but is especially
suitable
for high quality welding. GRINDING
In manual
Note:
Do
not
use
wheel
for
other
jobs
or
tugsten
can
become
contaminated
cause lower
weld quality
the relatively small arc is ideal for thin sheet material or controlled penetration (in the root run of and
pipe
welds).
Because deposition rate can be quite low (using a separate filler rod) MMA or MIG may be preferable for
thicker material and for fill passes in thick-wall pipe welds.
WELDING GAS SELECTION CHART GUIDE
T
GAS LENS
TIG
TIG WELDING
ARGON
Ar-CO2-O2
MILD STEEL
√
X
STAINLESS STEEL
√
X
LOW ALLOY STEEL
√
X
ALUMINIUM
X
√
TUNGSTEN ELECTRODE
FILLER WIRE
WORK PIECE
WORK PIECE
AC / DC WELDING
Alternating current (AC) is electricity that switches direction back and forth so the voltage also periodically reverses because the current changes direction. Typical AC currents are what you would expect to see from your
electrical outlets in your home and often used in higher voltage devices such as household appliances. AC current changes its polarity 120 times per second with a 60-hertz current. Reversed polarity (AC) results in deeper
penetration. In Alternate Current (AC) welding, since the current and the magnetic field of the arc reverse direction many times a second, there is no net deflection of the arc.
Applications of AC Welding
AC welding can be used to weld magnetic metals. This cannot be done with DC welding. AC welding is ideal for
the following types of welds:
• Downhand heavy plate
• Fast fill
• Aluminum TIG welding with high frequency
34
The primary advantage of using AC welding is that it allows the weld operator to weld on magnetized
materials. In AC current, the current changes direction and is not affected by magnetism. The arc remains stable
and is easier to control.
AC / DC WELDING - CONTINUE
AC welding is also the preferred method for:
• TIG welding aluminum, because the current supports welding at a higher temperature.
• Making repairs on machinery because the machinery usually has a magnetized field and is older and may
have rusty areas where there is concern about the higher heat penetration that can occur with DC welding.
• Seam welding in shipbuilding because the current settings can often be higher than those used in DC
welding and a deeper penetration of plate metals can be obtained.
The biggest drawback to using AC welding is the quality of the weld. It is not as smooth as DC welding
because of the continuous change in directional flow and there is likely to be more spatter.
Different waveforms for AC welding on TIG welding machines
There will be different waveforms depending on the parameter settings. This gives the welder even more precise
control of the weld pool and the seam’s appearance. The flickering of the pulse arc can also be affected, reducing
the stress on the welder’s eyes in the process. There are also acoustic differences as noise is reduced.
AC
AC
AC
Waveform: Hard rectangle
Waveform: Soft rectangle
Waveform: Triangle
Switching between the plus and
minus pole is very fast.
The switching between plus and
minus is therefore not quite as
abrupt as it is with the hard
rectangle function, and not as
delayed as in sine mode.
The variation of the current between
plus and minus is distributed
entirely evenly over time.
Effect:
The goal is an extremely fast zero
crossing of the half-wave. The
arc becomes highly stable while
a very loud, “hard” arc noise is
produced at the same time.
Applications:
This “hard” arc is still the standard
today for many welders as they
have always been used to it and
it offers good welding properties.
There is also the advantage that
the arc can be used on very thick
oxide layers.
Effect:
The arc combines the advantage
of the sine and the hard rectangle
modes. The result is a relatively
stable arc, with relatively low/quiet
background noise.
Applications:
Due to these properties, the option
“soft rectangle” for TIG welding
systems is also the universal setting– for a wide range of welding
tasks.
Effect:
The zero crossing is therefore
rather slow in comparison to
the other waveforms. However,
the even distribution of the
current-time area achieves a
higher peak current, although the
mean current remains the same.
This in turn results in a particularly
high arc pressure. Acoustically, the
arc is only slightly louder than the
sine setting.
Applications:
The high arc pressure means the
triangle setting is particularly well
suited for root passes.
Applications of DC Welding
Welding with DC is best used for:
• Hard facing
• Build-up of heavy deposits
• Overhead or vertical welding
• Stainless steel TIG welding
• Single carbon brazing
• Cutting tap
As a rule of thumb, DC is preferred for welding because:
It produces a smoother weld and there is less spatter because of the constant linear direction of the current.
It maintains a constant and stable arc and is thus is easier to handle and more reliable than AC current.
Machinery that uses DC current is generally cheaper and easier to use.
It welds thinner metals better than AC current.
Overall Strength of Welds
Overall the strength of the weld can be determined by many factors, such as:
• Proper electrode, welding apparatus and procedures;
• Properties of the materials being welded-magnetic vs. non-magnetic;
• Proper edge preparation-the cleaner the edge, the better the weld;
• Current settings – DC vs. AC;
• Speed of travel – the angle of the electrode needs to be maintained throughout the length of the joint as it is
being welded.
A strong weld can be achieved in both AC welding and DC welding so long as you weld with the current and
polarity appropriate for the material being welded. One doesn’t necessarily, always and everywhere, produce
a better weld than the other. It’s a matter of choosing the right one for your job.
35
PULSE TIG WELDING
TIG welding with the pulse feature is most often done for thin metals such as aluminum and can also be
used with copper and varieties of steel. Pulsing can be set up with a foot pedal or as a setting on your TIG
welder, but when should you use pulsing? There are some very specific applications for pulsing with a TIG
welder and then there are times when it can just come in handy to get a job done better. Here’s a look at
some TIG welding with pulse applications:
Greater Control Over the Heat
Pulse for TIG is all about improving your control when you don’t want to burn through your metal work piece.
Using the pedal or setting up the pulse will moderate the heat as you weld and ensure you have enough heat
present at the joint without laying a ton of filler metal into the joint or burning through the metal.
Too much metal in the weld joint could create a headache for your welding project, as you’ll have to stop to
grind it down and then clean up the metal before you can start welding again. The pulse setting gives you far
more control over the welding process without compromising the strength and integrity of your weld.
When You Need a Neat Weld
Pulsing your weld is an easy way to create a smooth, clean weld for a TIG welding application.
Getting yourself in a steady pulsing rhythm is an ideal way to keep moving the puddle forward or walking the
cup along a weld joint.
TIG welding is most often used when there is little margin for error and the metal is especially thin.
By pulsing along the weld joint you can moderate the amount of filler metal you add so that it’s evenly
distributed and you create a great looking weld.
Minimal Movement
If you’re in a tight spot and you don’t have a lot of room to maneuver, pulsing your TIG welder is one way to
glide along the weld joint, adding filler metal as you go, without worrying about introducing too much heat
and filler. The main thing for this application will be a steady hand on the torch and an even pace for the filler
metal. If this is a particularly tight spot, you can pick up shorter torches that have a very small head and can
fit in a variety of spaces. With TIG welding you can reach a tight spot much better than with a stick welder
and you can control the input of filler metal better than with MIG, making it a great option when welding is
particularly challenging.
Moving Faster with High Speed Pulse
Given some practice, many welders can effectively weld at the high speed of 150 pulses per second,
creating neat welds in far less time. While you wouldn’t want to try a faster pulsing speed if you’re not used to
it, many welders prefer to move either really slow or really fast in order to create a steady rhythm. Pulsing at
around 20 per second has led some welders to make uneven, spotty welds.
This would be especially useful in a fabrication shop where you’re seeing a lot of the same metal work
pieces over and over and over again. If you have a handle on how fast you need to move on each piece,
then there’s a good chance you can bump up the pulsing rate to improve your welding speed.
Cycle Time
WELD CURRENT
Background Time
Peak Current Level
Background
Current Level
TIME
Peak Time
36
STICK AC / DC SETUP
Note: The below image shows setup for DCEP / Negative Polarity
(Most Common application)
6. Select Stick AC or DC mode
2. Connect Electrode holder
to the
terminal
2. Connect earth Clamp
to the
terminal
OFF
1
2
Plug the machine 10Amp input power lead into
the wall socket, ensuring that the power
switch on the machine is in the OFF position.
Assemble Arc and Earth leads into the
welding terminals depending on requirements
of electrodes. Refer to your electrode packet
for polarity and current requirements.
3
4
Connect earth clamp firmly to work-piece
ensuring that the clamp makes good
contact with bare metal.
Take electrode holder and insert bare metal
rod end of electrode and twist red handle to
clamp electrode.
DCEP: Electrode connected to Positive (+) output socket.
DCEN: Electrode connected to Negative (-) output socket.
Note: Pictures may vary from your machine model
37
STICK AC / DC SETUP - CONTINUED
ON
5
Ensure the electrode / electrode holder is
not near the work-piece or can earth out,
turn the machine on using the mains power
switch. The front displays will light up and
the cooling fan will start.
8
Rotate right knob to adjust the welding
voltage.
Press 1 time on the right knob for
Hot Start. This control provides extra power
when the weld starts to counteract the high
resistance of the electrode and workpiece
as the arc is started.
Press 2 times on the right knob for
Arc Force. This control boosts the welding
power if its senses the welding voltage is
getting too low. The higher the arc force
adjustment, the higher the minimum
voltage that the power source will allow.
This effect will also cause the welding
current to increase.
6
Press Menu button and adjust knob to select
Stick AC or DC then press knob to confirm.
MMA (DC): Choosing the connection of
DCEN or DCEP according to the different
electrodes. Please refer to the electrode
manual.
MMA (AC): No requirements for polarity
connection.
Function
Setting
Hot Start
0 ~ 10
Arc Force
0 ~ 10
Average Metal Thickness
Electrode Size
1.0 - 2.0mm
2.0mm
2.0 - 5.0mm
2.6mm
5.0 - 8mm
3.2mm
8.0mm +
4.0mm
Amperage Selection Guide
9
38
7
Rotate left knob to adjust welding current.
Note: Pictures may vary from your machine model
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
Please see table on page 39 as
a guide to Welding Parameters.
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.
MANUAL METAL ARC PROCESS (MMA WELDING)
When an arc is struck between the metal rod (electrode) and the workpiece, both the rod and workpiece
surface melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas and slag
which protects the weld pool from the surrounding atmosphere. The slag will solidify and cool and must be
chipped off the weld bead once the weld run is complete (or before the next weld pass is deposited).
The process allows only short lengths of weld to be produced before a new electrode needs to be inserted in
the holder. Weld penetration is low and the quality of the weld deposit is highly dependent on the
skill of the welder.
TYPES OF ELECTRODES
Arc stability, depth of penetration, metal deposition rate and positional capability are greatly influenced by the
chemical composition of the flux coating on the electrode. There are many types of Electrodes, and these
are generally matched to the base metal. For example if welding Mild Steel then select a Mild Steel (General
Purpose Electrode). Electrodes are identified by a universal numbering system (AWS Type code).
Base Metal
Electrode Type
Type
Mild Steel
Mild Steel General Purpose
6013
Stainless Steel
Stainless Steel 316L
316L
Dissimilar Metals
Dissimilar 680
312
Cast Iron
Nickel Arc 98
Ni99
High Strength Steel
Low Hydrogen
TC16
Electrodes are often packed in sealed packaging to keep moisture out. However, if a pack has been opened
or damaged, it is essential that the electrodes are redried according to the manufacturer’s instructions.
ARC FORCE
Also called Dig and Arc Control. Gives a power source variable additional amperage during 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
ELECTRODE SIZE SELECTION
Electrode size selection will be determined by the
thickness of the section being welded. A thicker
section will need a larger diameter electrode. The
table below shows the maximum size of electrodes
for average thicknesses of section (based on
General Purpose 6013 Electrode).
Average Metal Thickness
Electrode Size
1.0 - 2.0mm
2.0mm
2.0 - 5.0mm
2.6mm
5.0 - 8mm
3.2mm
8.0mm +
4.0mm
WELDING CURRENT
Welding current level is determined by the size
of electrode - the normal operating range and
current are recommended by manufacturers. Typical
operating ranges for a selection of electrode sizes
are illustrated in the table. As a rule of thumb when
selecting a suitable current level, an electrode will
require about 40 Amps per millimetre (diameter).
Therefore, the preferred current level for a 4mm
diameter electrode would be 160 Amps, but the
acceptable operating range is 140 to 180 Amps.
It is important to match the machine to the job
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
39
SET UP OF WIRE SPOOL & WIRE FEED UNIT
1
Open the side door of the machine.
5
Remove the Drive Roller Cover. Check the
Drive roller is matched to the wire size for
the job. Note: Correct wire side on roller
to face into machine when fitting. Then
replace the Drive Roller Cover.
See Page 41 for drive roller size and type.
Drive roller
size (mm)
2
Remove the Spool Hub Nut and place
spool of wire on Spool Hub.
Note: Wire to roll from under spool into
the wire guide inlet tube
6
3
40
4
Roller Groove
V Groove - Mild Steel
U Groove - Aluminium
V-knurled - Gasless Wire
Ensure you hold the spool and check
tension to stop wire spool unraveling
Replace Spool Hub Nut and adjust firmly without too much pressure.
Release the Wire Feed Tensioning Knob
by pulling it to the left.
Take the end of the wire and feed into the
Guide tube until it passes to the Inlet Tube,
& out of the Euro connection Approx 3-5cm
7
Put down Wire Tensioning Arm so it locks
into position, and turn the Wire Feed
Tensioning Knob to gently tighten.
Note: Pictures may vary from your machine model
MIG TORCH SET
1
Attach the Euro Connect MIG torch to the
machine feeding the wire into the liner.
Tighten MIG Torch conanector to machine.
5
Press the trigger. This will feed the wire
through the torch. Release button when
wire appears at the end of the torch.
6
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.
7
Trim wire to the end of the nozzle.
A
B
3
Remove nozzle (A) and tip (B) from torch.
ON
4
Plug machine into 240V and switch to the
ON position on the back of machine.
MACHINE DRIVE ROLLER SIZE GUIDE (NOTE: MACHINE WILL RUN UP TO 1.2MM WIRE)
10mm
30mm
PART No:
DESCRIPTION
Knurled Drive Roller For Gasless Wire
RK302210.08.10
Drive Roller 0.8/1.0mm Knurled 30 x 22 x 10mm
RK302210.09.12
Drive Roller 0.9/1.2mm Knurled 30 x 22 x 10mm
RK302210.10.12
Drive Roller 1.0/1.2mm Knurled 30 x 22 x 10mm
U Grooved Drive Roller For Aluminium Wire
RU302210.06.08
Drive Roller 0.6/0.8mm U Groove 30 x 22 x 10mm
RU302210.08.09
Drive Roller 0.8/0.9mm U Groove 30 x 22 x 10mm
RU302210.08.10
Drive Roller 0.8/1.0mm U Groove 30 x 22 x 10mm
RU302210.09.12
Drive Roller 0.9/1.2mm U Groove 30 x 22 x 10mm
V Grooved Drive Roller For Solid Wire
RV302210.06.08
Drive Roller 0.6/0.8mm V Groove 30 x 22 x 10mm
RV302210.08.10
Drive Roller 0.8/1.0mm V Groove 30 x 22 x 10mm
RV302210.09.12
Drive Roller 0.9/1.2mm V Groove 30 x 22 x 10mm
RV302210.10.12
Drive Roller 1.0/1.2mm V Groove 30 x 22 x 10mm
Note: Pictures may vary from your machine model
41
MIG TORCH LINER INSTALLATION / REPLACEMENT
1
Lay the MIG torch out
straight and flat on the
ground and remove the
front end parts
4
Carefully feed the new
liner into the torch lead all
the way out the end of the
torch
7
Re install tip and tighten
using the tool provided and
re attach nozzle to torch.
Do NOT over tighten, or you
may damage the tip holder
4
Tighten the retaining nut up
all the way
DESCRIPTION
ORIGINAL REF
Remove the liner retaining
nut from the euro torch end
5
Fit the retaining nut and
slightly tighten the nut about
half way
3
Carefully remove the liner
completely from the torch
6
Snip the new liner 3mm past
the end of the torch neck
PART NO.
Steel Liners
Teflon Liners for Aluminium
42
8
2
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.BT3
Blue teflon liner 0.6 - 0.9mm 3mt
126.0005
92.04.BT4
Blue teflon liner 0.6 - 0.9mm 4mt
126.0008
92.04.RT3
Red teflon liner0.9 - 1.2mm 3mt
124.0011
92.04.RT4
Red teflon liner0.9 - 1.2mm 4mt
124.0012
92.04.RT5
Red teflon liner0.9 - 1.2mm 5mt
124.0015
Note: Pictures may vary from your machine model
Proper MIG Torch inspection
Prior to welding, ensure all connections are tight and that consumables and equipment are in good condition
and free from damage. Start with the front of the gun and work your way back to the feeder. A tight neck
connection is essential to carry the electrical current from the welding cable to the front-end consumables.
Also, be sure to visually inspect the handle and trigger to check there are no missing screws or damage.
The cable should be free of cuts, kinks and damage along the outer cover. Cuts in the cable can expose the
internal copper wiring and create a potential safety hazard to the welding operator. In addition, these issues
can lead to electrical resistance that causes heat buildup — and ultimately cable failure.
Consumables
MIG gun front-end consumables are exposed to heat and spatter and therefore often require frequent
replacement. However, performing some simple maintenance can help extend consumable life and improve
gun performance and weld quality. The gas diffuser provides gas flow to the weld pool and also connects to
the neck and carries the electrical current to the contact tip. Make sure all connections are tight, and check
the diffuser’s O-rings for cracks, cuts or damage. The nozzle’s main role is to focus the shielding gas around
the weld pool. Watch for spatter buildup in the nozzle, which can obstruct gas flow and lead to problems
due to inadequate shielding coverage. Use MIG pliers to clean spatter from the nozzle. The contact tip is
the last point of contact between the welding equipment and the welding wire. Keyholing of the contact tip
is a concern to watch for with this consumable. This occurs when the wire passing through the tip wears an
oblong-shaped slot into the diameter of the tip. Keyholing can put the wire out of center and cause problems
such as an erratic arc. If you are experiencing wire feeding issues, try changing the contact tip or switching to
a larger-size contact tip. Tips that look worn should be replaced.
Spatter removal from inside and outside the nozzle using MIG pliers
Build up of spatter can
cause damage to
nozzle and tip
Keyholing of the
contact tip
Final thoughts
Taking the time for preventative maintenance can pay off in less downtime in the long run. Along with that,
always remember to properly store your MIG gun consumables to help you achieve the best results and
extend the life of your equipment. When not in use, the MIG gun should be stored in a coiled position, either
hanging or lying flat, such as on a shelf. Do not leave MIG gun on the floor of the shop, where there is a
chance the cable could be run over, kinked or damaged.
WELDING PRODUCTS TO HELP PROLONG, MAINTAIN
AND PRODUCE BETTER WELDS
Bossweld Aerosol Anti Spatter Spray
This silicon free spatter release coating is a colourless
film which stops weld spatter from sticking to welding equipment,
work pieces & fixtures. Easily removed before painting or finishing.
Bossweld Tip Dip Gel
Non toxic water based dipping gel for the prevention
of weld spatter adherence to MIG torch parts.
This silicon free compound is used to prolong
the life of nozzles & tips.
Bossweld 8 Ways MIG Welding Pliers
Handy 8 function welders pliers. Functions include,
nozzle removal, tip removal, cleaning inside of nozzle
and wire cutting.
43
LIST OF ERROR CODES
Error Type
Thermal relay
Welding
machine
Switch
Accessory
Communication
Code
E01
E02
E03
E04
E09
E10
E11
E12
E13
E14
E15
E16
E20
E21
E22
E23
E30
E31
E40
E41
Description
Over-heating (1st thermal relay)
Over-heating (2nd thermal relay)
Over-heating (3rd thermal relay)
Over-heating (4th thermal relay)
Over-heating (Program default)
Phase loss
N/A
No gas
Under voltage
Over voltage
Over current
Wire feeder over load
Button fault on operating panel when
switch on the machine
Other faults on operating panel when
switch on the machine
Torch fault when switch on the machine
Torch fault during normal working process
Cutting torch disconnection
N/A
Connection problem between wire feeder
and power source
Communication error
JOB PROGRAM DISPLAY INTRODUCTION
1
2
3
4
5
1. JOB button: Press it for 3s to enter JOB programs and press it for 1s to save parameters.
(Can’t save when all slots are in used)
2. Parameters display: Selected parameter settings.
3. JOB number display: 10 slots to save your parameter settings
4. L parameter knob: Rotate it to turn the page and press it to delete the parameters.
44
5. R parameter knob: Rotate it to select JOB program number and press it to load the
selected JOB program number.
BOSSWELD
BINZELBINZEL
STYLESTYLE
24 MIGMIG
TORCH
BZ
24 BOSSWELD
TORCH COMPLETE
PART NO.
DESCRIPTION
92.ER.24.3
BZ Style 24 MIG Torch 3m
92.ER.24.4
BZ Style 24 MIG Torch 4m
92.ER.24.5
BZ Style 24 MIG Torch 5m
BOSSWELD BINZEL STYLE 24 MIG TORCH SPARE PARTS
CO
CL
10
M6 Standard Duty
M6 Heavy Duty
M6 Aluminium
PART NO.
DESCRIPTION
ORIGINAL REF
PART NO.
DESCRIPTION
ORIGINAL REF
92.02.24.CO
Adjustable conical nozzle ø 12.5 STD
145.0075
92.01.15.06
Adjustable cylindrical ø 17mm
145.0022
Contact tip 0.6mm x M6 x 6mm dia x
25mm long
140.0008
92.02.24.CL
92.02.24.10
Adjustable tapered nozzle ø 10mm
145.0123
92.01.15.08
Contact tip 0.8mm x M6 x 6mm dia x
25mm long
140.0059
92.01.15.09
Contact tip 0.9mm x M6 x 6mm dia x
25mm long
140.0177
92.01.15.10
Contact tip 1.0mm x M6 x 6mm dia x
25mm long
140.0253
92.01.25.06
Contact tip 0.6mm x M6 x 8mm dia x
25mm long
140.0005
92.01.25.08
Contact tip 0.8mm x M6 x 8mm dia x
25mm long
140.0051
92.01.25.09
Contact tip 0.9mm x M6 x 8mm dia x
25mm long
140.0169
92.01.25.10
Contact tip 1.0mm x M6 x 8mm dia x
25mm long
140.0242
92.01.25.12
Contact tip 1.2mm x M6 x 8mm dia x
25mm long
140.0379
92.01.25.14
Contact tip 1.4mm x M6 x 8mm dia x
25mm long
140.0516
92.01.25.16
Contact tip 1.6mm x M6 x 8mm dia x
25mm long
140.0555
92.01.M6A09
Contact tip 0.9mm x M6 Al x 8mm dia x
28mm long
141.0004
92.01.M6A10
Contact tip 1.0mm x M6 Al x 8mm dia x
28mm long
141.0006
92.01.M6A12
Contact tip 1.2mm x M6 Al x 8mm dia x
28mm long
141.0072
PART NO.
DESCRIPTION
ORIGINAL REF
92.05.24.M6
Tip Holder M6
142.0003
PART NO.
DESCRIPTION
ORIGINAL REF
92.05.24
Gas Diffuser - Ceramic
012.0017
92.05.24R
Gas Diffuser - Red Rubber
N/A
PART NO.
DESCRIPTION
ORIGINAL REF
92.06.24
Swan Neck
012.0001
Steel Liners
PART NO.
PART NO.
DESCRIPTION
Teflon Liners for Aluminium
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
ORIGINAL REF
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
92.09.HANDLE
Ergonomic handle with screws
N/A
92.09.BWT
Trigger
N/A
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.BT3
Blue teflon liner 0.6 - 0.9mm 3mt
126.0005
92.04.BT4
Blue teflon liner 0.6 - 0.9mm 4mt
126.0008
92.04.RT3
Red teflon liner0.9 - 1.2mm 3mt
124.0011
92.04.RT4
Red teflon liner0.9 - 1.2mm 4mt
124.0012
92.04.RT5
Red teflon liner0.9 - 1.2mm 5mt
124.0015
45
BOSSWELD 17 SERIES 150AMP & 26 SERIES 180AMP TIG TORCH COMPLETE & SPARES
BACK CAP
INSULATOR
COLLET
PART NO.
DESCRIPTION
95.17F.4.1.SW9A
Bossweld 17 Series TIG Torch 4mt 9 pin Plug
95.17F.8.1.SW9A
Bossweld 17 Series TIG Torch 8mt 9 pin Plug
95.26F.4.1.SW9A
Bossweld 26 Series TIG Torch 4mt 9 pin Plug
95.26F.8.1.SW9A
Bossweld 26 Series TIG Torch 8mt 9 pin Plug
COLLET BODY
GAS LENS COLLET BODY
ALUMINA CUP
46
TORCH BODY
GAS LENS ALUMINA CUP
PART NO.
DESCRIPTION
9957Y04
Back Cap Short
9557Y05
Back Cap Medium
PART NO.
DESCRIPTION
955Y02
Back Cap Long
9518CG
Torch Body Front Insulator
9554N01
Torch Body Front Insulator Lens Cup
PART NO.
DESCRIPTION
9510N21
Collet 0.5mm
9510N22
Collet 1.0mm
9510N23
Collet 1.6mm
PART NO.
DESCRIPTION
9510N24
Collet 2.4mm
95WP26
Torch Head
9510N25
Collet 3.2mm
954WP26V
Torch Head with Valve
9510N20
Collet 4.0mm
95WP26F
Flex Torch Head
95WP26FV
Flex Torch Head with Valve
PART NO.
DESCRIPTION
9545V24
Gas Lens Collet 1.0mm
9545V25
Gas Lens Collet 1.6mm
9545V26
Gas Lens Collet 2.4mm
9545V27
Gas Lens Collet 3.2mm
9545V28
Gas Lens Collet 4.0mm
PART NO.
DESCRIPTION
9510N29
Collet Body 0.5mm
9510N30
Collet Body 1.0mm
9510N31
Collet Body 1.6mm
9510N32
Collet Body 2.4mm
9510N28
Collet Body 3.2mm
95406488
Collet Body 4.0mm
PART NO.
DESCRIPTION
9510N50
Alumin Cup Size 4
PART NO.
DESCRIPTION
9510N49
Alumin Cup Size 5
9554N18
Gas Len Alumin Cup Size 4 - 6.0mm
9510N48
Alumin Cup Size 6
9554N17
Gas Len Alumin Cup Size 5 - 8.0mm
9510N47
Alumin Cup Size 7
9554N16
Gas Len Alumin Cup Size 6 - 9.5mm
9510N46
Alumin Cup Size 8
9554N15
Gas Len Alumin Cup Size 7 - 11.0mm
9510N45
Alumin Cup Size 10
9554N14
Gas Len Alumin Cup Size 8 - 12.7mm
9510N44
Alumin Cup Size 12
9554N19
Gas Len Alumin Cup Size 11 - 17.5mm
BOSSWELD SPOOL GUN 180/250AMP - 9PIN
This spool gun is the perfect solution for welding soft alloys, especially aluminium where feeding the aluminium
MIG wire is always a challenge due to birds nesting, tangles and feedability problems. A spool gun overcomes
these issues by providing a reliable solution that delivers the wire at the gun point with a short feed length
compared to a standard mig gun length of at least 3 metres.
FEATURES
• Suits the X series range of machines.
• Primarily used for MIG (GMAW) welding
of aluminium and aluminium alloys.
• Can be also used for MIG welding of
mild steel and stainless steel.
SPX15 SPOOL GUN
NO. PART NO.
DESCRIPTION
97.SPX15.4.9 Bossweld 4mt spool gun SPX15 9 pin Plug
Current
180 Amps
97.SPX15.8.9 Bossweld 8mt spool gun SPX15 9 pin Plug
Duty Cycle
@ 40˚C
60% @ 180 Amps CO2
60% @ 150 Amps MIX
1
92.05.15
2
92.01.M6A09 Contact Tip 0.9mm x M6 Al x 8mm dia x 28mm long
Tip holder with spring l/hand
Cooling
Air
Wire Size
0.6mm > 1.0mm
92.01.M6A10 Contact Tip 1.0mm x M6 Al x 8mm dia x 28mm long
3
92.01.15.08
Contact Tip 0.8mm x M6 x 6mm dia x 25mm long
92.01.15.09
Contact Tip 0.9mm x M6 x 6mm dia x 25mm long
92.01.15.10
Contact Tip 1.0mm x M6 x 6mm dia x 25mm long
92.01.25.06
Contact Tip heavy duty 0.6mm x M6 x 8mm dia x 25mm long
92.01.25.08
Contact Tip heavy duty 0.8mm x M6 x 8mm dia x 25mm long
92.01.25.09
Contact Tip heavy duty 0.9mm x M6 x 8mm dia x 25mm long
92.01.25.10
Contact Tip heavy duty 1.0mm x M6 x 8mm dia x 25mm long
5
92.02.15.10
Adjustable tapered nozzle ø 10mm
6
92.02.15.CO
Adjustable conical nozzle ø 12 mm
7
92.02.15.CL
Adjustable cylindrical nozzle ø 19mm
4
2
5
1
6
3
7
4
SPX24 SPOOL GUN
NO. PART NO.
DESCRIPTION
97.SPX24.4.9 Bossweld 4mt spool gun SPX24 9 pin Plug
97.SPX24.8.9 Bossweld 8mt spool gun SPX24 9 pin Plug
1
92.05.24R
Gas Diffuser - Red Rubber
2
92.05.24
Gas Diffuser - Ceramic
3
92.05.24.M6
Tip Holder M6
4
92.01.M6A09 Contact Tip 0.9mm x M6 Al x 8mm dia x 28mm long
92.01.M6A10 Contact Tip 1.0mm x M6 Al x 8mm dia x 28mm long
92.01.M6A12 Contact Tip 1.2mm x M6 Al x 8mm dia x 28mm long
5
92.01.15.08
Contact Tip 0.8mm x M6 x 6mm dia x 25mm long
92.01.15.09
Contact Tip 0.9mm x M6 x 6mm dia x 25mm long
92.01.15.10
Contact Tip 1.0mm x M6 x 6mm dia x 25mm long
92.01.25.08
Contact Tip heavy duty 0.8mm x M6 x 8mm dia x 25mm long
92.01.25.09
Contact Tip heavy duty 0.9mm x M6 x 8mm dia x 25mm long
92.01.25.10
Contact Tip heavy duty 1.0mm x M6 x 8mm dia x 25mm long
92.01.25.12
Contact Tip heavy duty 1.2mm x M6 x 8mm dia x 25mm long
7
92.02.24.10
Adjustable tapered nozzle ø 10mm
8
92.02.24.CO
Adjustable conical nozzle ø 12.5 mm
9
92.02.24.CL
Adjustable cylindrical nozzle ø 17mm
6
Current
250 Amps
Duty Cycle
@ 40˚C
60% @ 250 Amps CO2
60% @ 220 Amps MIX
Cooling
Air
Wire Size
0.6mm > 1.2mm
7
4
1
8
5
9
3
6
2
47
HELPFUL INFORMATION
Filler Metal
Notes
Solid Mild Steel wire
• Use Industry standard - copper coated ER70S-6 Steel
MIG Wire. This requires a shielding gas (CO2 or argon/
CO2 mix),excellent results on panel steel.
Gasless Flux cored Mild Steel Wire
(Known as GS)
• Use Industry standard flux cored ER71T-GS Steel MIG
Wire. This does not require a shielding gas.
• Suitable 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.
• Produces smoke and splatters.
Drive Feed Roller Selection
It is important that correct drive roller is used
to get the best results.
Solid mild steel
Stainless steel wire
“V” groove Roller. Roller has a small V shaped groove
to guide the wire.
Flux cored wire
“V Knurled” roller (assists in gripping as wire is soft)
Aluminium wire
“U” groove Roller (assist in gripping as wire is softest)
Polarity
Machine can be used in both DC + and DC - modes
Wire Type -Gas shield wire
(solid or CO2 shielded flux)
“-” earth
Self-shielded
Flux core Wire
“+” earth
Aluminium
3m only for push torch, Teflon liner, “U” groove roller, alloy
tips or one size larger, argon shielding wire
OPERATIONAL ENVIRONMENT
•
•
•
•
•
•
48
•
Height above sea level ≤1000m
Operation temperature range -10°C ~ +40°C
Air relative humidity is below 90%( 20°C)
Preferably sit the machine above floor level,
ensure the maximum angle does not exceed 15 degrees.
Protect the machine against heavy rain and against direct sunshine.
The content of dust, acid, corrosive gas in the surrounding air or substance
must not exceed normal standards.
Take care that there is sufficient ventilation during welding.
There must be at least 30cm free distance between the machine and wall.
MIG WIRE FEED TROUBLE SHOOTING
The following chart addresses some of the common WIRE FEED problems during MIG welding.
Issue
Possible Reason
Suggested Remedy
No wire feed
• Wrong mode selected
• Check that the TIG/MMA/MIG selector switch
set to MIG position
Inconsistent / interrupted
wire feed
• Adjusting wrong dial
• Be sure to adjust the wire feed and voltage
dials for MIG welding. The amperage dial is for
MMA and TIG welding mode.
• Select the correct polarity for the wire being
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
• Wrong polarity selected
• Incorrect wire speed setting
• Voltage setting incorrect
• MIG torch lead too long
• MIG torch lead kinked or too
sharp angle being held
• Contact tip worn, wrong size,
wrong type
• Liner worn or clogged (the
most common causes of bad
feeding)
• Wrong size liner
• Blocked or worn inlet guide
tube
• Wire misaligned in drive roller
groove
• Incorrect drive roller size
• Wrong type of drive roller
selected
• Worn drive rollers
• Drive roller pressure too high
• Too much tension on wire
spool hub
• Wire crossed over on the
spool or tangled
• Contaminated MIG wire
• 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 to replace the liner.
• Install the correct size liner
• Clear or replace the inlet guide tube
• Locate the wire into the groove of the drive
roller
•Fit the correct size drive roller e.g.0.8mm wire
requires 0.8mm drive roller.
• Fit the correct type roller (e.g. knurled rollers
needed for flux cored wires).
• Replace the drive rollers
Can flatten the wire electrode causing it to
lodge in the contact tip - reduce the drive roller
pressure.
• Reduce the spool hub brake tension
• Remove the spool untangle the wire or
replace the wire.
• Use clean dry rust free wire. Do not lubricate
the wire with oil, grease etc.
49
TROUBLE SHOOTING
Issue
Possible Reason
Power indicator is not lit,
fan does not work and no
output current
• Welder is not plugged into
power supply
• Circuit breaker may have
operated
• Main power switch may not be
in the ON position
• Check that the welder is plugged into the
240V mains outlet and is switched on.
• Check that the mains fuse or breaker has not
operated.
• Check that the main switch on the rear of the
unit is in the on position.
Power indicator is lit, fan
works, no output current
• Output connectors may be
disconnected or damaged
• Welding cables or earth clamp
not connected properly
• Check output connectors are connected
properly and are not damaged
• Check connections and that workpiece is free
of paint and rust at connection point
Over temperature indicator
is on, no output current
• Duty cycle of the unit has
been exceeded. .
• Allow the unit to cool for 20 minutes
Output current is not stable. • Earth clamp connection loose
• Mains Voltage is not constant
• Loose welding cables
• Leads reversed
• 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 +/_
Hot Welding Clamp
Welding clamp rated current is
too small,
Replace with larger size welding clamp.
Excessive Spatter
• Wire feed speed set too high
• Voltage too high
• Wrong polarity set
• Select lower wire feed speed
• Select a lower voltage setting
• Select the correct polarity for the wire being
used
• Bring the torch closer to the work
• Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
• Use clean dry rust free wire. Do not lubricate
the wire with oil, grease etc
• Check the gas is connected, check hoses, gas
valve and torch are not restricted. Set the gas
flow between 6-12 l/min flow rate. Check hoses
and fittings for holes, leaks. Protect the welding
zone from wind and drafts
• Change contact tip.
• Stick out too long
• Contaminated base metal
Contaminated MIG wire
• Inadequate gas flow or too
much gas flow
• Worn contact tip
Porosity - small cavities or
holes resulting from gas
pockets in weld metal
• Wrong gas
• Inadequate gas flow or too
much gas flow
• Moisture on the base metal
• Contaminated base metal
• Contaminated MIG wire
50
Suggested Remedy
• Loose gas connection
• Check that the correct gas is being used
• Check the gas is connected; check hoses,
gas valve and torch are not restricted. Set the
gas flow between 10 - 15 l/min flow rate. Check
hoses and fittings for holes, leaks etc. Protect
the welding zone from wind and drafts
• Remove all moisture from base metal before
welding
•Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
• Use clean dry rust free wire. Do not lubricate
the wire with oil, grease etc.
Check and tighten connection.
TROUBLE SHOOTING - CONTINUED
Issue
Porosity - small cavities or
holes resulting from gas
pockets in weld metal
Possible Reason
Suggested Remedy
• Gas nozzle clogged with
spatter, worn or out of shape
• Missing or damaged gas
diffuser
• MIG torch euro connect
O-Ring missing or damaged
• Clean or replace the gas nozzle
• Replace the gas diffuser
• Check and replace the O-Ring
Wire stubbing during
welding
• Holding the torch too far away • Bring the torch closer to the work and
maintain stick out of 5-10mm
• Welding voltage set too low
• Increase the voltage
• Wire speed set too high
• Decrease the wire feed speed
Lack of Fusion − failure of
weld metal to fuse
completely with base metal
or a proceeding weld bead
• Contaminated base metal
• Not enough heat input
• Improper welding technique
• Too much heat
• Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
• Select a higher voltage range and /or adjust
the wire speed to suit
Keep the arc at the leading edge of the weld
pool. Gun angle to work should be between 5
& 15° Direct the arc at the weld joint
Adjust work angle or widen groove to access
bottom during welding, Momentarily hold arc
on side walls if using weaving technique
• Select a lower voltage range and /or adjust
the wire speed to suit Increase travel speed
Excessive Penetration −
weld metal melting through
base meta
Poor in incorrect joint
preparation
• Material too thick. Joint preparation and
design needs to allow access to bottom of
groove while maintaining proper welding wire
extension and arc characteristics Keep the arc
at the leading edge of the weld pool and
maintain the gun angle at 5 & 15° keeping the
stick out between 5-10mm
Lack of Penetration −
shallow fusion between weld
metal and base metal
• Not enough heat input
• Select a higher voltage range and /or adjust
the wire speed to suit Reduce travel speed
• Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
Error Codes display on
screen (E01 to E41)
A range of trouble shooting in
• Thermal relay
• Welding machine
• Switch
• Accessory
• Communication
• Contaminated base metal
Check page 13 for the list of error code’s
descriptions
51
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