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BOSS TIG 160HF

、

200HF 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 TIG 160HF

Page 1: ...MODEL BOSS TIG 160HF BOSS TIG 200HF Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system First Edition September 2008 Manual No B0807 ...

Page 2: ... 4 03 DC pulse TIG welding 15 5 0 POWER SUPPLY CONTROLS INDICATORS AND REATURES 16 6 0 BASIC TIG WELDING GUIDE 17 6 01 Electrode Polarity 17 6 02 Tungsten Electrode Current Ranges 17 6 03 Tungsten Electrode Types 17 6 04 Guide for Selecting Filler Wire Diameter 17 6 05 Shielding gas selection 18 6 06 TIG welding parameters for low carbon low alloy steel pipe 18 6 07 Welding parameters for steel 18...

Page 3: ...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 4: ...ct 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 5: ...ess 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...

Page 6: ...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 7: ...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 8: ...d 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 9: ... 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 weldin...

Page 10: ...ference Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is p...

Page 11: ... can be operated at a given output without causing overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal ope...

Page 12: ...rating Manual 3 0 OPERATOR CONTROLS 3 01 TIG HF Series Controls Figure 2 1 The function switch TIG mode MMA mode 2 7 Pin Socket Used for the TIG torch switch only Figure 3 Pin Function 2 TIG torch switch 3 TIG torch switch Table 4 ...

Page 13: ...Hz Low frequency pulse the pulse frequency can output 2Hz 8 Down Slope Time and Post Flow Time 9 Gas Outlet 10 Positive Socket TIG connect the work lead MMA connect the electrode holder 11 Negative Socket TIG connect the TIG torch MMA connect the work lead 12 Input Power Cable 13 Gas Inlet 14 Ground Screw WARNING When the welder is connected to the primary supply voltage the internal electrical co...

Page 14: ...rent Down Slope Time This parameter operates in TIG modes only and is used to set the time for the welding current to ramp down this control is used to eliminate the crater that can form at the completion of a weld Post Flow t2 This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation o...

Page 15: ...red to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for TIG HF series WARNING Befor...

Page 16: ...rminal l Connect TIG torch to negative terminal l Switch machine on l Set DC TIG mode l Set welding current control see table 8 4 03 DC pulse TIG welding l Connect work lead to positive terminal l Connect TIG torch to negative terminal l Switch machine on l Set pulse high pulse low position l Set welding current control see table 8 Workpiece thickness mm Tungsten diameter mm Welding current A Fill...

Page 17: ...w frequency pulse TIG welding The pulse frequency may output the 2Hz 3 7 Pin socket 4 Down slope time and post flow time control Uses in adjusts when the welding receiving arc the output current automatic weaken to the zero needing the time the knob shows is the actual hour the unit for the second and post flow time is fixed 5s 5 Welding currents control Uses in adjusting the welding current 6 War...

Page 18: ...ctrode sizes 6 03 Tungsten Electrode Types Tungsten type Ground finish Welding Application Features Color code Thoriated 2 DC w elding 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 ra...

Page 19: ...TIG 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...

Page 20: ... sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types f...

Page 21: ...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 22: ...lue damage 4 Power PCB damage 5 Gas regulator turned off 1 Replace TIG torch 2 Replace gas hose 3 Replace solenoid value 4 Replace power PCB 5 Turn on 4 TIG mode no high frequency starts d Gas flow continues have spark 1 Welding cable disconnected 2 Poor tungsten 1 Reconnect 2 Replace tungsten 5 TIG mode unstable welding Arc 1 Wrong tungsten 2 TIG torch bad contact or damage 3 Gas flow control is ...

Page 23: ...de 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...

Page 24: ...de 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 ...

Page 25: ...ns 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 regulato...

Page 26: ... 25 BOSS TIG 160HF 200HF Operating Manual 10 0 PARTS LIST ...

Page 27: ... 26 BOSS TIG 160HF 200HF Operating Manual ...

Page 28: ... 1 1 2 1 3KITP000106011 BOARD PCB MOSFET 7 820 016A 1 1 2 2 3KITP000506021 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 ...

Page 29: ...ET MOSFET DIODE 8 610 117 9 9 16 16 2 20 2FPPP8610118 BRACKET MOSFET DIODE 8 610 118 2 2 2 21 2FP7840003 INSULATOR HEATSINK 1 1 2 21 2FP7840002 INSULATOR HEATSINK 1 1 2FP7854011 SPACER NYLON 凹 D5 8 8 8 8 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 3KITP000107010 BOARD PCB POWER TIG...

Page 30: ... 2 2 2 27 4KCD221BK SWITCH 1 1 1 1 28 4KYZPN8D24 KNOB 1 1 1 1 29 4KYZPN8E20R3 KNOB 1 1 1 1 30 4FANCA1238 FAN COVER 1 1 1 1 32 4JFT20X27 MOUNT NPRN JJ30 4 4 4 4 33 4FAN001SA1238 FAN 1 1 1 1 34 2PST8634001 INSULATOR FAN 1 1 1 1 35 4WP16S5002 RECEPTACLE 7 PIN 1 1 1 1 36 481CC2KV103 CAPACITOR 3KV103 1 1 1 1 37 8HPU4X6BK001 GAS HOSE 4 6 0 28 0 28 0 37 0 37 4V2FDLEDD5GN LED GN 2 2 2 2 38 4V2FDLEDS01D5 L...

Page 31: ...pped outputting and giving the red candle demonstration warning 11 3 Ambient temperatures high when big electric current long time continuous working the welding machine has stopped because of the heat outputting gets down until the temperature drop only then restores 11 4 When welding machines do not use temporarily its depository should maintain dryly cleanly The environment relative humidity is...

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