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MODEL 

•

 

BOSS ARC 140 

•

 

BOSS ARC 160 

 
 
 
 
 

Operating Manual 

(Owner’s Manual) 

 
 
 

IMPORTANT: Read these instructions before installing, operating, or servicing this system. 

 
 

Second Edition                                                  Manual No. B0802

Summary of Contents for ARC 140

Page 1: ...MODEL BOSS ARC 140 BOSS ARC 160 Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system Second Edition Manual No B0802 ...

Page 2: ......

Page 3: ...OLS INDICATORS AND REATURES 14 6 0 BASIC TIG WELDING GUIDE 15 6 01 Electrode Polarity 15 6 02 Tungsten Electrode Current Ranges 15 6 03 Tungsten Electrode Types 15 6 04 Guide for Selecting Filler Wire Diameter 15 6 05 Shielding gas selection 16 6 06 TIG welding parameters for low carbon low alloy steel pipe 16 6 07 Welding parameters for steel 16 7 0 BASIC ARC WELDING GUIDE 17 7 01 Electrode polar...

Page 4: ...SEC Seconds Remote outputs control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current t2 Gas Post Flow Time 2T GTAW t1 Gas Pre Flow Time 4T GTAW VRD Voltage Reduction Device Circuit Repeat Function GTAW Negative Spot Function GTAW Positive High Frequency Starting GTAW Gas Input Lift Start GTAW Gas Output ...

Page 5: ... negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of BOSS is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN BOSS S ...

Page 6: ...s can be dangerous and hazardous to your health l Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume l Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases l The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the different processes You must be v...

Page 7: ...may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table Do not cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed safe li...

Page 8: ...trical parts Disconnect input power conductors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage l Lift unit with handle on top of case l Use handcart or similar device of adequate capacity l If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 9: ...rd have been insulated Installation Location Be sure to locate the welder according to the following guidelines l In areas free from moisture and dust l In areas free from oil steam and corrosive gases l In areas not exposed to direct sunlight or rain l Ambient temperature between 10 degrees C to 40 degrees C l In areas not subjected to abnormal vibration or shock l Place at a distance of 304 79mm...

Page 10: ...he input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding ...

Page 11: ...rheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal operating temperature Continually exceeding the duty cycl...

Page 12: ...cator 3 AC Power Indicator 4 Main Power Switch 5 Positive Socket TIG connect the work lead MMA connect the electrode holder 6 Negative Socket TIG connect the TIG torch MMA connect the work lead 7 Input Power Cable 8 Ground Screw WARNING When the welder is connected to the primary supply voltage the internal electrical components maybe at primary potential with respect to earth ...

Page 13: ...anual 3 02 Weld parameters description Figure 3 BOSS ARC Seriesfront panel with parameter description Parameter Description Welding Current This parameter sets the welding current Table 4 Weld parameter description for BOSS ARC Series ...

Page 14: ... to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 4 Set up for BOSS ARC Series WARNING Before...

Page 15: ...A 10 50 50 150 150 250 Table 5 4 02 DC TIG welding l Connect work lead to positive terminal l Connect TIG torch to negative terminal l Switch machine on l Set welding current control see table 6 l Use TIG torch with value control Workpiece thickness mm Tungsten diameter mm Welding current A Filler wire diameter mm Argon Gas flow L min 0 3 0 5 1 1 6 5 30 3 8 0 5 1 2 1 6 2 10 50 1 2 1 6 4 8 1 2 2 1 ...

Page 16: ...REATURES Figure 5 BOSS ARC Series front panel 1 Welding currents control Uses in adjusting the welding current 2 Warning indicator Red colored light instruction welding machine overload 3 AC power indicator Green colored light instruction power source is normal 4 Main Power switch ...

Page 17: ...ctrode sizes 6 03 Tungsten Electrode Types Tungsten type Ground finish Welding Application Features Color code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc starting Long life high current carrying capacity Red Ceriated 2 DC welding of mild steel stainless steel copper aluminium magnesium and their alloys Longer Life More stable arc Easier starting Wider current ran...

Page 18: ...G welding parameters for low carbon low alloy steel pipe 6 07 Welding parameters for steel Base metal thickness mm DC current for mild steel A DC current for stainless steel A Tungsten diameter mm Filler rod diameter if require mm Argon gas flow rate litres min Joint type 1 0 35 45 40 50 20 30 25 35 1 0 1 6 5 7 butt corner lap fillet 1 2 45 55 50 60 30 45 35 50 1 0 1 6 5 7 butt corner lap fillet 1...

Page 19: ...ections necessary to give proper fusion of weld and base metal Types of Electrodes Arc welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for...

Page 20: ...t over 25psi as normal preventive maintenance At the time of the cleaning a full inspection of the welding machine and setup should be performed Check warning labels on the machine for readability replace if necessary Check input and output connections as well as frame ground connections to the machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring...

Page 21: ...s blown 3 Indicator damage 4 Relay PCB damage for ARC 160 5 Indicator light is open circuit 1 Check input power or replace main power switch 2 Replace primary fuse 3 Replace indicator light 4 Replace relay PCB 5 Replace indicator light 2 The AC power indicator light on and welding arc can not be established 1 Input voltage unstable 2 Diode PCB damage 1 Connect stabilizer or reset power switch 2 Re...

Page 22: ... is connected to the terminal B No gas flowing to welding region C Torch is clogged with dust D Gas hose is cut E Gas passage contains impurities F Gas regulator turned off G Torch valve is turned off H The electrode is too small for the welding current A Connected the electrode to the terminal B Check the gas lines for kinks or breaks and gas cylinder contents C Clean torch D Replace gas hose E D...

Page 23: ... too large for joint C Insufficient gap D Incorrect sequence A Increase welding current B Use smaller diameter electrode C Allow wider gap D Use correct build up sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy cold plate B Welding current is too low C Wrong electrode angle D Travel speed of electrode is too high E Sc...

Page 24: ... supply voltage Defective control circuit Have an accredited BOSS service agent inspect then repair the welder 3 Welding current reduces when welding Poor work lead connection to the work piece Ensure that the work lead has a positive electrical connection to the work piece 4 No gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities C Gas regulator ...

Page 25: ... 23 BOSS ARC 140 160 Operating Manual 10 0 PARTS LIST ...

Page 26: ... 24 BOSS ARC 140 160 Operating Manual ...

Page 27: ...6021 BOARD PCB DIODE 7 820 010A 02 1 2 2 3KITP000506035 BOARD PCB DIODE 7 820 010A 11 1 2 2 3KITP000106022 BOARD PCB DIODE 7 820 017 02 1 2 2 BOARD PCB DIODE 7 820 017 09 1 2 3 2HS7061062 HEATSINK LEFT LOWER 1 1 2 4 2HS7061063 HEATSINK LEFT UPPER A 1 1 2 5 2HS7061064 HEATSINK LEFT UPPER B 1 1 2 6 2HS7061060 HEATSINK RIGHT UPPER 1 1 2 7 2HS7061061 HEATSINK RIGHT LOWER 1 1 2 3 2HS7061053 HEATSINK LE...

Page 28: ...8 8 8 8 2 22 4BFTDQ001D5 SPACER NYLON 凸 D5 8 8 8 8 2FP7854015 SPACER NYLON 凹 D4 2 2 2 2 2 23 4BFTDQ003D3BK SPACER NYLON 凸 D3 2 2 2 2 2 24 4ABKBPC3510 RECTIFIER 2 2 2 2 3 3KITP000107015 BOARD PCB POWER MMA 7 820 002F 01 1 1 1 1 4 3KITP000509000 BOARD PCB RELAY INPUT 7 820 000A 1 1 8 3KITP002801010 BOARD PCB SENSOR 7 828 019A 02 Inside 1 1 9 3BB7725033 BUS BAR POSITIVE 1 1 9 3BB7725032 BUS BAR POSIT...

Page 29: ... 1 Welding machines rear panels meet the plume to have good to turn on the earth grounding by guarantees the welder safety When welder operation should wear protects the mirror the glove puts on protects the clothing 11 2 When the electrical network voltage is higher than 240V 260V the out put will appear the class the overload the welding machine automatically has stopped outputting and giving th...

Page 30: ... 5 6 1XS4 1 2 1XS5 1 2 3 4 5 6 1XS11 1 2 3 4 5 6 7 8 9 10 11 12 1CNX 1 2 3 1J1 AP5 PWM PCB FP7 829 004A 1 2 3 4 5 6 7 8 9 10 11 12 13 1CNY AP3 MOSFETPCB FP7 820 016A 3TP1 3X1 1 3XP1 1 1 3XP1 2 1 5 1 1 1 1 Red Black over current PWM 1 2 3 4 5 6 7 3XP3 1 5 1 QC5 1 QC4 1 1 1 2 3 4 5 1XS3 1 3XS2 1 1 3XS2 2 1 3XS2 3 1 3XS2 4 1 3XS2 5 1 3XS2 6 1 1 1 1 1 1 A P4 Diode PCB FP7 820 017 09 1 4W2 F6x20 1 4W1 ...

Page 31: ... 4 5 6 1XS4 1 2 1XS5 1 2 3 4 5 6 1XS11 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1CNX 1 2 3 1J1 AP5 PWMPCB FP7 829 004A 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1CNY AP3 MOSFETPCB FP7 820 016A 3TP1 3X1 1 3XP1 1 1 3XP1 2 1 5 1 1 1 1 Red Black over current PWM 1 2 3 4 5 6 7 3XP3 1 5 1 QC5 1 QC4 1 1 1 2 3 4 5 1XS3 1 3XS2 1 1 3XS2 2 1 3XS2 3 1 3XS2 4 1 3XS2 5 1 3XS2 6 1 1 1 1 1 1 A P4 DiodePCB FP7 820 017 09 1 4W2 F6x20...

Page 32: ...11 12 13 1CNY AP3 MOSFETPCB FP7 820 005B 3X1 1 5 1 1 1 1 Red Black over current PWM 1 2 3 4 5 1XS3 AP4 Diode PCB FP7 820 010a 11 4X1 ST1 17AM 105 4X2 4X3 Thermostat 1 1 1 2 4XS2 1 2 4XS1 AP2 Power PCB FP7 820 002F 01 1 2XS21 1 2XS20 1 2 3 4 2XS7 1 2 3 2XS6 1 2 2XS2 1 2XS14 1 2XS15 1 2XS13 1 2XS17 1 2XS16 1 2XS11 1 2XS10 1 2XS12 1 2XS19 1 2XS18 1 2 3 2XS3 1 2 2XS5 1 2 2XS4 1 2 3 2XS1 1 1 1 1 1 1 1 ...

Page 33: ... 11 12 13 1CNY AP3 MOSFETPCB FP7 820 005B 3X1 1 5 1 1 1 1 Red Black over current PWM 1 2 3 4 5 1XS3 AP4 Diode PCB FP7 820 010a 11 4X1 4X2 4X3 ST1 17AM 105 Thermostat 1 1 1 2 4XS2 1 2 4XS1 AP2 Power PCB FP7 820 002F 01 1 2XS21 1 2XS20 1 2 3 4 2XS7 1 2 3 2XS6 1 2 2XS2 1 2XS14 1 2XS15 1 2XS13 1 2XS17 1 2XS16 1 2XS11 1 2XS10 1 2XS12 1 2XS19 1 2XS18 1 2 3 2XS3 1 2 2XS5 1 2 2XS4 1 2 3 2XS1 1 1 1 1 1 1 1...

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