BossWeld S140 Manual Download

Page: 3 / 24

CONTENTS PAGE

WARRANTY 4

BOX CONTENTS

WARNINGS 6

MACHINE CARE / SAFETY INSTRUCTIONS

WORK AREA SAFETY

MAINTENANCE & DISPOSAL / DUTY CYCLE

FRONT & REAR PANEL LAYOUT

STICK / MMA WELDING SETUP

GENERAL MMA WELDING

12-13

TIG WELDING SETUP

14-16

TIG TORCH AND REGULATOR NOT SUPPLIED

GENERAL TIG WELDING

TUNGSTEN PREPARATION

MACHINE CONSUMABLES

19-22

AND COMMON WEAR PART

TROUBLE SHOOTING

Summary of Contents for S140

Page 1: ...INVERTER DC MMA ARC WELDER MANUAL S140 S180 2 YEAR LIMITED WARRANTY ...

Page 2: ... 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 pool Gas or flux prevents oxidisation in the weld Weld with or without gas Point and pull the trigger Great for maintenance small ...

Page 3: ... SAFETY 8 MAINTENANCE DISPOSAL DUTY CYCLE 9 FRONT REAR PANEL LAYOUT 10 STICK MMA WELDING SETUP 11 GENERAL MMA WELDING 12 13 TIG WELDING SETUP 14 16 TIG TORCH AND REGULATOR NOT SUPPLIED GENERAL TIG WELDING 17 TUNGSTEN PREPARATION 18 MACHINE CONSUMABLES 19 22 AND COMMON WEAR PART TROUBLE SHOOTING 23 ...

Page 4: ...ing 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 machine only and does not include T...

Page 5: ...S140 S180 Inverter DC MMA Arc Welder Box Contents 1 BOSSWELD S140 or S180 Inverter DC MMA Arc Welder 2 Electrode Holder Lead 3 Welding Earth Lead 4 Carry Strap 5 Cable Lead tidy 6 Owners Manual not shown 1 2 4 5 3 ...

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: ...use Always keep extension leads away from the welding zone moisture and any hot materials WELDING SURFACES Do not weld containers or pipes that hold or have held flammable liquids or combustible gases or pressure Do not weld on coated painted or varnished surfaces as the coatings may ignite or can give off dangerous fumes WORK PIECE When welding the work piece will remain at high temperature for a...

Page 9: ...00 180 Amps 90 Amps 0 Amps 27 2 Volts 23 6 Volts 22 8 Volts For example this means when the machine is set at a current of 180 Amps it can only weld for One and a half Minutes in a Ten minute period The power source is protected by a built in temperature protection device This will activate if the machine is operated in excess of its amperage and duty cycle rating Points to Current machine will ou...

Page 10: ...t Adjustment Knob 4 Positive Output Connection Socket 5 Negative Output Connection Socket REAR PANEL 6 Mains Power Switch 10Amp S140 Mains Power Switch 15Amp S140 7 240V AC Mains Power Cord 8 Cooling Fan 2 3 1 4 5 6 7 8 Note Warranty will be void if 15Amp plug is ground down ...

Page 11: ...contact with bare metal Assemble Arc and Earth leads into the welding terminals depending on requirements of electrodes Twist the connections to lock in and ensure a good connection Refer to your electrode packet for polarity and current requirements DCEP Negative Polarity most common application Earth clamp connector into the negative terminal Electrode holder connector into the positive terminal...

Page 12: ...ding current is forced across a gap between the electrode tip and the workpiece A welder must be able to strike and establish the correct arc easily and quickly The scratching method is easier for beginners The electrode is moved across the plate inclined at an angle as you would strike a match As the electrode scratches the plate an arc is struck When the arc has formed withdraw the electrode mom...

Page 13: ...lidify and cool and must be chipped off the weld bead once the weld run is complete or before the next weld pass is deposited The process allows only short lengths of weld to be produced before a new electrode needs to be inserted in the holder Weld penetration is low and the quality of the weld deposit is highly dependent on the skill of the welder TYPES OF ELECTRODES Arc stability depth of penet...

Page 14: ...ntry 400214 Bossweld Argon Dual Stage Regulator bottom entry 17 Series Complete Air Cooled TIG Torch Part Number 95 17V 4 1 DA25 Plug the machine 10Amp EVO 140 or 15Amp EVO 180 input power lead into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Install the TIG Torch to the machine by connecting the Dinse Connector to the Negative Output Connection Socket th...

Page 15: ...ead and ensure back cap and collet body are screwed in firmly 3 Select your required current by turning the Welding Parameter Adjustment Knob Turn the machine on using the mains power switch The front displays will light up and the cooling fan will start 6 7 Connect earth clamp firmly to work piece ensuring that the clamp makes good contact with bare metal 5 MACHINE SET UP TIG WELD CONTINUED Note ...

Page 16: ...as Remember to turn it off when finished welding 8 9 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 be liable or responsible for the loss of any gas Note It is advisable to run a few test welds using scra...

Page 17: ...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 welds Because deposition rate can be quite low using a separate filler rod MMA or MIG may be preferable for thicker material and for fill passes in thick wall pipe welds TIG is also widely applied...

Page 18: ...nation For this reason AC is used when welding materials with a tenacious surface oxide film such as aluminium ARC STARTING The welding arc can be started by scratching the surface forming a short circuit It is only when the short circuit is broken that the main welding current will flow However there is a risk that the electrode may stick to the surface and cause a tungsten inclusion in the weld ...

Page 19: ...2 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 9545V24 Gas Lens Collet 1 0mm 9545V25 Gas Lens Collet 1 6mm 9545V26 Gas Lens Collet 2 4mm 9545V27 Gas L...

Page 20: ...elding CODE DESCRIPTION 500088 Bossweld Spring Handle Chipping Hammer CODE DESCRIPTION 500080 Bossweld 4 Row Engineer Wire Brush Wood Handle Handy Pack Electrodes Handy packs are the ideal solution for small welding jobs and repairs Available in 4 diameter sizes including 1 6mm 2 0mm 2 6mm and 3 2mm Handy packs ranges include General Purpose Stainless Steel Dissimilar Metals Low Hydrogen and Cast ...

Page 21: ...cket has heavy duty sewing Features Heavy duty chrome leather Double studs for extra protection Several sizes available Heavy duty sewing Bossweld Leather Welding Blanket Chrome leather welding blanket Ideally suited to covering items to protect against weld spatter Commonly used in panel industry Features Heavy duty chrome leather blanket Excellent heat resistance Several sizes available For the ...

Page 22: ...Coated 2 4mm 1Kg 300102H Bossweld Tobin Bronze Flux Coated 3 2mm 1Kg 300103H Bossweld Nickel Bronze Flux Coated 2 4mm 1Kg 300108H Bossweld Nickel Bronze Flux Coated 3 2mm 1Kg 300109H Bossweld Manganese Bronze Flux Coated 2 4mm 1Kg 300112H Bossweld Manganese Bronze Flux Coated 3 2mm 1Kg 300113H TYPE SIZE PKT PART NO Bossweld Silicon Bronze 1 6mm 1Kg 300135H Bossweld Silicon Bronze 2 4mm 1Kg 300136H...

Page 23: ... Check the welding cable connectors are tight in the sockets 3 Check the earth clamp connection to the work piece 4 Check the welding leads are not reversed 1 Welding clamp rated current is too small replace with larger size welding clamp 1 Output polarity is incorrect reverse output connector TROUBLE SHOOTING OPERATIONAL ENVIRONMENT Height above sea level 1000m Operation temperature range 10 40 C...

Page 24: ... 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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