BossWeld M150 Manual Download

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CONTENTS PAGE

WARRANTY 4

BOX CONTENTS

WARNINGS 6

MACHINE CARE / SAFETY INSTRUCTIONS

WORK AREA SAFETY

MAINTENANCE & DISPOSAL / GAS BOTTLE

FRONT & REAR PANEL LAYOUT

MACHINE INSIDE

DUTY CYCLE / POWER SUPPLY WARNING

WIRE FEEDER SETUP

MIG TORCH SETUP

GASLESS MIG WELDING SETUP

16-17

GAS MIG WELDING SETUP

18-19

GENERAL MIG WELDING

20-22

COMMON WEAR PART

BZ15 MIG TORCH PARTS BREAK DOWN

DRIVE ROLLERS

BZ15 MIG TORCH REPLACEMENT

HELPFUL INFORMATION & TROUBLE SHOOTING

24-27

Summary of Contents for M150

Page 1: ...INVERTER MIG WELDER GAS GASLESS MANUAL M150 2 YEAR LIMITED WARRANTY ...

Page 2: ... with both Gas and Gasless MIG wire Ideal for around the home DIY workshop or rural applications We truly hope you enjoy using your welder 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 M MIG Simple to learn MIG Wire is fed through the gun to create the weld...

Page 3: ... FRONT REAR PANEL LAYOUT 10 MACHINE INSIDE 11 DUTY CYCLE POWER SUPPLY WARNING 12 WIRE FEEDER SETUP 13 MIG TORCH SETUP 14 GASLESS MIG WELDING SETUP 16 17 GAS MIG WELDING SETUP 18 19 GENERAL MIG WELDING 20 22 COMMON WEAR PART 23 BZ15 MIG TORCH PARTS BREAK DOWN DRIVE ROLLERS BZ15 MIG TORCH REPLACEMENT HELPFUL INFORMATION TROUBLE SHOOTING 24 27 ...

Page 4: ...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 mach...

Page 5: ...connect 3 Welding Earth Lead direct connect 4 Gas Hose 5 Dual Stage Argon Regulator 6 Cable Lead Tidy 7 Torch Spares 8 Drive Roller Installed in Machine 0 8 0 9 V Groove not shown Gasless Drive Roller 0 8 0 9mm for use with Gasless Wire not shown Gasless Drive roller has a jagged groove 9 Owners Manual not shown 1 2 3 4 5 6 7 ...

Page 6: ... 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 7: ...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 8: ...e 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 outd...

Page 9: ...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 10: ...r Light 3 Overload error indicator 4 Welding Speed Adjustment 5 Welding Voltage Control Knob 6 MIG Torch 7 Welding Earth Lead REAR PANEL 8 Mains Power Switch 9 Gas Input 10 240V AC Mains Power Cord 11 Cooling Fan 12 15 Amp Input Plug 4 2 1 3 5 11 7 8 9 6 10 12 ...

Page 11: ...oller E Guide Tube F Wire Feed Tensioning Knob G Wire Tensioning Arm H Idle Roller I Inlet tube J Wire Feed inching K Polarity Switching Terminal D D DCEN Polarity Switching Terminal Set for Gasless Welding DCEP Polarity Switching Terminal Set for Gas Welding DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY ...

Page 12: ... 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 Amps refer to the Current setting 15 60 100 150 Amps 78 Amps 60 Amps 21 5 Volts 17 8 Volts 17 Volts For example this means when the machine is set at a current of 150 Amps it can only weld for One and ha...

Page 13: ...side on roller to face into machine when fitting Then replace the Drive Roller Cover See Page 16 for drive roller size and type Put down Wire Tensioning Arm so it locks into position and turn the Wire Feed Tensioning Knob to gently tighten Replace Spool Hub Nut and adjust firmly without too much pressure Note Wire to roll from under spool into wire feeder Note Pictures may vary from your machine m...

Page 14: ... is straight and has no kinks while you feed the wire through it Trim wire to the end of the nozzle NOTE Wire speed will run a full speed when the trigger is pressed without making and arc Remove nozzle A and tip B from torch A B 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 3 7 6 4 4 Note Picture...

Page 15: ...ent 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 shield...

Page 16: ...ire Drive roller size mm MACHINE DRIVE ROLLER SIZE NOTE MACHINE WILL RUN UP TO 1 0MM WIRE 30mm 19mm Denotes driver rollers supplies with machine PART NO DESCRIPTION Knurled Drive Roller For Gasless Wire RK301019 06 08 Drive Roller 0 6 0 8mm Knurled 30 x 10 x 19mm RK301019 08 09 Drive Roller 0 8 0 9mm Knurled 30 x 10 x 19mm RK301019 08 10 Drive Roller 0 8 1 0mm Knurled 30 x 10 x 19mm U Grooved Driv...

Page 17: ... through the torch Release button when wire appears at the end of the torch NOTE make sure your torch is straight and has no kinks while you feed the wire through it 6 Refer to the chart on the front of the machine and set your voltage and wires speed dials to the according settings once you start to weld you can make finer adjustment to suit 9 NOTE It is advisable to run a few test welds using sc...

Page 18: ...re feeder 3 2 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 Ensure the polarity is correct for gas welding DCEP 4 Roller Groove V Groove Mild Steel U Groove Aluminium V knurled Gasless Wire Drive roller size mm Connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal 5 Swit...

Page 19: ...he machine and set your voltage and wires speed dials to the according settings once you start to weld you can make finer adjustment to suit 11 10 Fit gas regulator to the gas bottle and install gas hose to the gas 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 NOTE It is advisable to run a few test welds using sc...

Page 20: ...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 21: ...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 Argon o2 Argon Co2 Argon Note 1 The above amperage range is to be used as a guide only 2 Welding travel speed will affect the en...

Page 22: ...ring 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 SHIELDING GAS In addition to gener...

Page 23: ... Duty M6 Aluminium CL CO 10 GAS HOLDER GAS NOZZLE CONTACT TIP MACHINE DRIVE ROLLER SIZE NOTE MACHINE WILL RUN UP TO 1 0MM WIRE 30mm 19mm BZ15 BOSSWELD BINZEL STYLE DIRECT CONNECT MIG TORCH Please note This replacement torch must be replaced by Bossweld or an authorised service centre Failure to do so will void your machine warranty PART NO DESCRIPTION 92 ER M150DC Bossweld MIG Torch BZ15 x 2 5mt D...

Page 24: ...le 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 Producers smoke and splatters It is important that correct drive roller is used to get the best results V groove Roller Roll...

Page 25: ...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 26: ...ing Bring the torch closer to 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 Ad...

Page 27: ...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 Clear or replace the inlet guide tube Locate the wire into the groove of the drive ro...

Page 28: ... 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 Version 1 0 2019 ...

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