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BOSS Inverter Mig 250 Operating Manual

1.03 Transporting methods

These units are equipped with a handle for carrying purposes.

WARNING: ELECTRIC SHOCK can kill.

DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply

line before moving the welding power source.

WARNING:

FALLING EQUIPMENT can cause serious personal injury and

equipment damage.

l

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.

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Summary of Contents for Mig 250

Page 1: ...MODEL Inverter Mig 250 Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system First Edition October 2008 Manual No B0808 ...

Page 2: ......

Page 3: ...1 3 02 Inverter Mig 250 Control Methods 13 3 03 Weld Parameter Description 13 4 0 SET UP FOR MIG MAG 14 5 0 POWER SUPPLY CONTROLS INDICATORS AND REATURES 15 5 01 Basic MIG Welding Guide 16 5 02 Position of MIG GUN 16 5 03 Distance from the MIG Gun Nozzle to the Work Piece 16 5 04 Travel Speed 16 5 05 Electrode Wire Size Selection 16 5 06 Spot Welding Operation 17 6 0 MAINTENANCE 18 7 0 BASIC TROUB...

Page 4: ...W 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: ...act 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...

Page 6: ...cess 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 b...

Page 7: ...s 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 ...

Page 8: ...ectrical 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: ...cally conductive parts in the near vicinity of the operator which can cause increased hazard 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...

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

Page 11: ...wires Select the roller required with the chosen wire size marking facing outwards l Fit the electrode wire spool to the wire reel hub l Lift up the wire feeder pressure lever and lift the electrode wire to the entrance of the gun l Lower the pressure lever and with the gun lead reasonably straight feed the wire through the gun till to extend from the hole in the middle of contact tip l Regulate t...

Page 12: ...RNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal operating temperature Continually exceeding the duty cycle ratings can cause damage to the welding power source NOTICE Due to variations that can occur in manufacture products claimed performance voltages ratings all capacities measuremen...

Page 13: ...sitive Terminal 50mm Screw receptacle 8 Negative Terminal 50mm Screw receptacle 9 Terminal Use to connect the torch 10 Down Slope Voltage Control Optional 11 Down Slope Amperage Control Optional 12 Meter Selection 13 Inductance Control Inside 14 Digital Meter 15 Warning Indicator Activates under the following conditions Input voltage is too low too high Thermal overload 16 AC Power Indicator Light...

Page 14: ...gulation D Current regulation E Current regulation F Short line Short line G Short line Short line H Short line I Spot switch J Spot switch K Solenoid valve L Solenoid valve M WF2 motor Spool gun motor N WF2 motor Spool gun motor Table 4 WARNING When the welder is connected to the primary supply voltage the internal electrical components maybe at primary potential with respect to earth ...

Page 15: ...cription Welding Current This parameter sets the welding current Spot Time MIG only The welding current can be set and be controlled according to the setting time This mode of welding is used to melt the top bottom plates together to form a nugget between them Burnback Time MIG only Burnback time is the difference between the wire feed motor stopping and switching off of the welding current The Bu...

Page 16: ...rc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for Inverter Mig 250 WARNING Before connect...

Page 17: ... 2T Spot 4T 3 Spot Time Control a spot welding nozzle required 4 14 Pin Receptacle Used to connect the wire feeder 5 Wire Feed Speed Control 6 Voltage Control 7 Down Slope Amperage Control Optional 8 Down Slope Voltage Control Optional 9 Meter Selection 10 Voltage Indicator 11 Speed Indicator 12 Amperage Indicator 13 Digital Meter 14 Warning Indicator 15 AC Power indicator ...

Page 18: ...e diameter and dimensions of the work piece l If the wire speed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool If the wire speed is too slow for the welding voltage large drops will form on the end of the electrode wire causing spatter Suppose that wire speed is constant if the welding voltage is too high large drops will form on the end of the electr...

Page 19: ...gher deposition rates therefore greater productivity will be achieved by using smaller electrode wire The Inverter Mig 250 is a particularity efficient MIG welder with the 0 9mm 1 2mm steel wire in spray transfer mode 0 9mm wire cost approx 10 more than 1 2mm but is deposited approx 15 faster High current density or smaller diameter wire also gives deeper penetration as shown Figure 8 Wire penetra...

Page 20: ...to the machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring of machine for loose or frayed connections tighten or repair as necessary It would also be advisable to check connections to wire feeders fixtures etc at this time Any damaged cable or hoses should be replaced DANGER HIGH VOLTAGE is present internally even with the control power switch i...

Page 21: ... damage 1 Turn on the gas system 2 Repair or replace 3 Repair or replace 4 Repair or replace 4 Turn on torch control switch c Have gas flow Have wire feed No output 1 Disconnect the work piece to the work ground cable 2 Wire feed control PCB damage 1 Reconnect the ground cable and tighten the work piece 2 Repair or replace 5 Faulty welding arc control 1 The MIG torch damage 2 Faulty setting 3 Main...

Page 22: ...ply l Internal gas hose in the power supply Ensure the hose from the solenoid valve to the MIG gun adaptor has not fractured and that it is connected to the MIG gun adaptor l Welding in a windy environment Shield the weld area from the wind or increase the gas flow l Welding dirty oily painted oxidized or greasy plate Clean contaminates off plate l Distance between the MIG gun Keep the distance be...

Page 23: ...eed roller groove shape or size Debris is fed into the liner where it accumulates thus reducing wire feed ability l Incorrect or worn contact tip The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip When using soft electrode wire such as al...

Page 24: ...age by reducing wire speed control or increasing the voltage selection switches 5 Irregular weld shape A Incorrect voltage and current settings Convex voltage too low Concave voltage too high B Wire is wandering C Incorrect shielding gas D Insufficient or excessive heat input A Adjust voltage and current by adjusting the voltage selection switches and the wire speed control B Replace the contact t...

Page 25: ...tact tip replace faulty components B Have an accredited BOSS service agent investigate the faulty 5 Wire feeds when the gun trigger switch is depressed but arc can not be established Poor or no work lead connection Clean work clamp area and ensure good electrical contact 6 Wire continues to feed when the gun trigger switch is released The mode selector switch has been set to 4T latch operation Set...

Page 26: ... 24 BOSS Inverter Mig 250 Operating Manual 8 0 PARTS LIST ...

Page 27: ... 25 BOSS Inverter Mig 250 Operating Manual Figure 9 ...

Page 28: ...46 BRACKET HEATSINK MOUNTING 2 2 17 2FPBM8610039 BRACKET HEATSINK MOUNTING I 2 2 18 2FPBM8610040 BRACKET HEATSINK MOUNTING II 2 2 19 2FPPP8610117 BRACKET MOSFET DIODE 8 610 117 16 2 21 2FP7840020 INSULATOR HEATSINK Inside 1 2FP7854011 SPACER NYLON 凹 D5 18 2 22 4BFTDQ001D5 SPACER NYLON 凸 D5 18 2FP7854012 SPACER NYLON 凹 D3 Inside 6 2 23 4BFTDQ003D3BK SPACER NYLON 凸 D3 Inside 6 2FP7854015 SPACER NYLO...

Page 29: ... 2 9 MOUNTING 1 33 2FBM8604046 BRACKET INDUCTOR MOUNTING 1 34 2FBM8604043 BRACKET MOTOR MOUNTING 1 35 2FPPT8040036 PANEL DOOR 2 36 BRACKET 14 PIN MOUNTING 1 37 2FP7854004 INSULATOR BULKHEAD FRONT 2 38 2FP7854008 INSULATOR BULKHEAD REAR 2 39 4SXJPG29 BUSHING STRAIN RELIEF PG29 1 40 2GS50CC001FP RECEPTACLE TWIST LOCK FEMALE POWER 2 41 4KCD221BK SWITCH 1 42 2FP7854018 PROTECTION FOR EURO CONNECTOR 1 ...

Page 30: ... on the earth grounding by guarantees the welder safety When welder operation should wear protects the mirror the glove puts on protects the clothing 9 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 the red candle demonstration warning 9 3 Ambient temperatures high whe...

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