BossWeld 660250 Page 3 Manual Download

Page: 3 / 48

CONTENTS PAGE

WARRANTY 4

BOX CONTENTS

WARNINGS 6-8

MACHINE CARE / SAFETY INSTRUCTIONS

WORK AREA SAFETY

MAINTENANCE & DISPOSAL / GAS BOTTLE

FRONT & REAR PANEL LAYOUT

MACHINE INSIDE

MACHINE CONTROLS PANEL

14-18

DUAL PULSE FUNCTION

WIRE SPOOL & WIRE FEED SET UP

MIG TORCH SETUP

LINER INSTALLATION / REPLACEMENT

DRIVE ROLLER SIZE

2T / 4T TRIGGER CONTROL INFORMATION

WAVE CONTROL

MIG TORCH AND CONSUMABLE CARE

STICK / MMA WELDING SETUP

19-20

GENERAL MMA WELDING

GASLESS MIG WELDING SETUP

22-24

GAS MIG WELDING SETUP

24-27

GENERAL MIG WELDING

28-31

TIG WELDING SETUP

32-33

LIFT ARC TIG

TUNGSTEN PREPARATION

GENERAL TIG WELDING

BZ24 MIG TORCH PARTS BREAK DOWN

26 TIG TORCH BREAKDOWN

HELPFUL INFORMATION & TROUBLE SHOOTING

39-42

Summary of Contents for 660250

Page 1: ...DUAL PULSE SYNERGIC MST INVERTER WELDER MANUAL POWERPULSE 250 2 YEAR LIMITED WARRANTY ...

Page 2: ... to feed through MIG torches such as aluminum wire In the JOB mode 100 different JOB records can be stored and called improve the quality of welding process Arc welding with the POWERPULSE 250 machine t is suitable for all positions welding for various plates made of stainless steel carbon steel alloyed steel etc Applications applied to pipe installment petrochemical architecture equipment car rep...

Page 3: ...CH SETUP 15 LINER INSTALLATION REPLACEMENT 16 DRIVE ROLLER SIZE 25 2T 4T TRIGGER CONTROL INFORMATION 17 WAVE CONTROL 17 MIG TORCH AND CONSUMABLE CARE 18 STICK MMA WELDING SETUP 19 20 GENERAL MMA WELDING 21 GASLESS MIG WELDING SETUP 22 24 GAS MIG WELDING SETUP 24 27 GENERAL MIG WELDING 28 31 TIG WELDING SETUP 32 33 LIFT ARC TIG 34 TUNGSTEN PREPARATION 35 GENERAL TIG WELDING 36 BZ24 MIG TORCH PARTS ...

Page 4: ... 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 web...

Page 5: ...ERPULSE 250PFC Inverter DC MIG Welder 2 3 metre 36 Series MIG Torch 3 Welding cable with electrode holder 4 Earth cable with earth clamp 5 Gas Hose 6 Dual Stage Argon Regulator 7 Torch Spares 8 Carry Strap 9 Drive Roller spare not shown 10 Operating Manual not shown 1 5 6 7 8 3 2 4 ...

Page 6: ...nd invisible ultraviolet and infrared rays that can burn eyes and skin Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Use suitable clothing made from durable flame resistant material to protect your skin and that of your coworkers from the arc rays Protect other nearby personnel with suitable ...

Page 7: ...nment deplete the oxygen content in the air resulting in death or injury Many gases used in welding are invisible and odorless Shut off shielding gas supply when not in use Always ventilate confined spaces or use approved air supplied respirator Electric and Magnetic Fields Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF The discussion on the effect...

Page 8: ... 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 elec...

Page 9: ...G 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 instruction...

Page 10: ...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 out...

Page 11: ...st Check with your local council authority for recycling advice MAINTENANCE DISPOSAL 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 ...

Page 12: ... Socket 3 Remote Connection Plug 9pin 4 Euro Torch Connection 5 Quick Connect Gas Valve 6 Negative Output Connection Socket REAR PANEL 7 Mains Power Switch 8 Water Cooling connector 9 Gas Input 10 240V AC Mains Power Cord 11 Cooling Fan 2 3 5 6 1 4 11 7 9 10 8 ...

Page 13: ...ity Change DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY NOTE For flux cored wire connect the Polar conversion line to Negative Welding Output Terminal connect the earth clamp to Positive Welding Output Terminal For ordinary wire connect the Polar conversion line to Positive Welding Output Terminal connect the earth clamp to Negative Welding Output Terminal 12 15 18 14 13 16 17 DCEN GASLESS DCEP ...

Page 14: ...10 0 to 10 0 The higher the value the longer arc length The lower the value the shorter the arc length Value will be displayed on the left digital display INDUCTANCE INDICATOR Adjustable from 10 0 to 10 0 Value will be displayed on the left digital display MATERIAL THICKNESS INDICATOR Value will be displayed on the right digital display This will vary depending on synergic program selection WIRE S...

Page 15: ...ss and hold the trigger and the amperage will begin to downslope at the rate you have selected on the downslope dial amperage will remain at this level until you release the trigger 4 Once you have released the trigger the arc will stop and the postflow gas will continue for a pre set amount of time S4T 1 Press the trigger and Hold The set preflow gas starts and the arc starts SPOT WELD 1 Hold the...

Page 16: ...ime during which welding current is applied to the metal sheets Adjustable from 0 10 sec DELTA PULSE CURRENT The difference between base current and peak current in pulse welding Adjustable from 20 200Amps DUAL PULSE FREQUENCY Set pulse frequency regulating the value of time T ripple pattern of density regulation Adjustable from 0 5 3 0Hz DUAL PULSE DUTY Set strong pulse time peak for penetration ...

Page 17: ...e trigger before the weld is finished If downslope is set the current will go through the downslope period before going to the end current set Adjustable from 10 200 END CURRENT ARC LENGTH Exists in S4T welding mode excessive arc length will lead to spatters and unsightly welds so it is necessary to set reasonable quantity Adjustable from 10 10 HYDRO COOLING Select water cooling ON or OFF SPOOL GU...

Page 18: ...ting due to exceeding duty cycle is detected and protection is activated When protection is activated welding output will be disabled until the safety system senses the overload has reduced sufficiently and indicator lamp goes out May also trigger if machine experiences an internal power circuit failure SYNERGIC FUNCTION This makes the setup of MIG welding more simple the operator simply sets the ...

Page 19: ...17 4 80 Ar 20 CO2 P15 CuSi3 1 0 8 8 9 Ar100 P16 CuSi3 1 2 1 1 8 9 Ar100 P17 CuAl8 1 2 1 1 8 9 Ar100 Synergic Dual Pulse Parameter Synergic MIG Parameter Dual pulse function introduction Dual pulse welding in single pulse welding with low frequency modulated pulse low frequency pulse frequency 0 5 3 0Hz Single pulse compared to dual pulse has the advantages of without welding swing weld automatic f...

Page 20: ...onnected to the negative socket this is known as DCEP However various electrodes require a different polarity for optimum results and careful attention should be paid to the polarity refer to the electrode manufacturers information for the correct polarity DCEP Electrode connected to output socket DCEN Electrode connected to output socket 1 Turn the power source on and press the TIG MMA MIG button...

Page 21: ...hine 5 Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator Check for Leaks 6 Connect the gas line to the machine inlet gas connector via the quick push lock connector located on the rear panel Check for Leaks 7 Connect the power cable of welding machine with the output switch in electric box on site 8 Carefully open the valve of the gas cylinder set the requ...

Page 22: ... 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 25 for drive roller size and type Push the Wire Tensioning Arms up and lock into position and turn the Wire Feed Tensioning Knobs to gently tighten Replace Spool Hub Nut and adjust firmly without too much pressure Note Pictu...

Page 23: ...d Do NOT over tighten or you may damage the tip holder and re attach nozzle to torch Note Pictures may vary from your machine model 1 3 5 7 6 4 2 MANUAL 0 6mm 0 8mm 0 9mm 1 0mm SYNERGIC MODE MANUAL Voltage Wire Speed SYNERGIC Adjustment ADJUSTMENT CO MIX FLUX 4T VRD 2T TIG MMA MIG WIRE MODE TRIGGER VRD WELD MODE GAS CHECK WIRE INCH V V A M min VOLTAGE AMPERAGE MIG INDUCTANCE MMA HOT START ARC FORC...

Page 24: ...nut up all the way Carfully remove the liner completely from the torch PART NO 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 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...

Page 25: ...e rate you have selected on the downslope dial amperage will remain at this level until you release the trigger 5 Once you have released the trigger the arc will stop and the postflow gas will continue for a pre set amount of time Note Pictures may vary from your machine model MACHINE DRIVE ROLLER SIZE NOTE MACHINE WILL RUN UP TO 1 0MM WIRE 30mm 10mm 10mm Denotes driver rollers supplies with machi...

Page 26: ... 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 wel...

Page 27: ...g 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 Base Metal Electrode Type Type Mild Steel Mild Steel General Purpose 6013 Stainless Steel Sta...

Page 28: ...rive roller is matched to the wire size and type Refer to Drive Feed Roller Selection on page 25 Note Wire to roll from under spool into wire feeder Set up the wire feed unit as per section Set up Wire Feed Unit 3 2 Install Euro connect MIG torch over the protruding wire line up the spring connectors and screw the Euro connector nut up firmly 4 Plug the machine 15Amp input power lead into the wall...

Page 29: ...chine on using the mains power switch Wait a few seconds whilst the machine powers up Remove nozzle and tip from torch and press the Wire Inch Button This will feed the wire through the torch Release button when wire appears at the end of the torch Press the Welding Mode Selection Button to select MIG 7 Note Pictures may vary from your machine model MANUAL 0 6mm 0 8mm 0 9mm 1 0mm SYNERGIC MODE MAN...

Page 30: ... use the Adjustment knob to change the parameter 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 4 Connect Mig Torch to the Euro Connection terminal NOTE Ensure connector nut is tighten firmly 6 Connect earth Clamp to the terminal 8 Select MIG mode 14 15 Fit gas regulator to bottle and instal...

Page 31: ...tall Euro connect MIG torch over the protruding wire line up the spring connectors and screw the Euro connector nut up firmly 4 Plug the machine 15Amp input power lead into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Drive roller size mm DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY Fit the Earth lead Dinse Plug to the positive terminal for gasless weldi...

Page 32: ...Button to select MIG MANUAL 0 6mm 0 8mm 0 9mm 1 0mm SYNERGIC MODE MANUAL Voltage Wire Speed SYNERGIC Adjustment ADJUSTMENT CO MIX FLUX 4T VRD 2T TIG MMA MIG WIRE MODE TRIGGER VRD WELD MODE GAS CHECK WIRE INCH V V A M min VOLTAGE AMPERAGE MIG INDUCTANCE MMA HOT START ARC FORCE 190S MANUAL 0 6mm 0 8mm 0 9mm 1 0mm SYNERGIC MODE MANUAL Voltage Wire Speed SYNERGIC Adjustment ADJUSTMENT CO MIX FLUX 4T V...

Page 33: ...3 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 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 ...

Page 34: ...at 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 Distance from the MIG Gun Nozzle to the Work Piece The electrode stick out from the MIG gun nozzle should be between 2 0mm ...

Page 35: ...tainless Steel Aluminium Mig Wire Gas Shielded Mig Wire Gas Shielded 0 8mm 0 9mm 1 2mm 0 8mm 0 9mm 1 0mm 1 2mm 0 8 1 0 40 50 1 2 50 60 50 70 1 6 65 80 75 95 90 110 2 0 75 90 85 105 90 115 3 0 95 120 125 135 110 130 110 135 120 140 4 0 140 155 145 155 135 150 140 160 145 170 6 0 175 190 150 175 155 180 165 190 8 0 200 210 220 250 185 220 190 230 10 0 220 240 240 265 220 250 12 0 235 250 250 Gas Arg...

Page 36: ...rial 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 wir...

Page 37: ...mally 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 CO...

Page 38: ...orkpiece surface In DC because arc heat is distributed approximately one third at the cathode negative and two thirds at the anode positive the electrode is always negative polarity to prevent overheating and melting However the alternative power 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 contam...

Page 39: ...re that the arc is reignited at each reversal of polarity HF sparks are generated across the electrode workpiece gap to coincide with the beginning of each half cycle APPLICATIONS TIG is applied in all industrial sectors but is especially suitable for high quality welding In manual welding the relatively small arc is ideal for thin sheet material or controlled penetration in the root run of pipe w...

Page 40: ...AL REF 92 04 BNL12 Brass swan neck liner 1 2mm 250mm 120 0018 92 04 BNL16 Brass swan neck liner 1 6mm 250mm 120 0041 PART NO DESCRIPTION ORIGINAL REF 92 09 HANDLE Ergonomic handle with screws N A 92 09 BWT Trigger N A PART NO DESCRIPTION ORIGINAL REF 92 01 15 06 Contact tip 0 6mm x M6 x 6mm dia x 25mm long 140 0008 92 01 15 08 Contact tip 0 8mm x M6 x 6mm dia x 25mm long 140 0059 92 01 15 09 Conta...

Page 41: ...ART 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 9510N49 Alumin Cup Size 5 9510N48 Alumin Cup Size 6 9510N47 Alumin Cup Size 7 9510N46 Alumin Cup Size 8 9510N45 Alumin Cup Size 10 9510N44 Alumin Cup Size 12 PART NO DESCRIPTION ...

Page 42: ...ble 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 It is important that correct drive roller is used to get the best results V groove Roller Roll...

Page 43: ...n position Check output connectors are connected properly and are not damaged Check connections and that workpiece is free of paint and rust at connection point Allow the unit to cool for 20 minutes 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 _ Replace w...

Page 44: ...o the work and maintain stick out of 5 10mm Increase the voltage Decrease the wire feed speed 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 gro...

Page 45: ... 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 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 recommende...

Page 46: ...loor 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 ...

Page 47: ...47 ...

Page 48: ...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 ...

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