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FRONT PANEL

1.  LCD Current Meter / Display
2.  Overload error indicator light
3.  Multi-function Control Knob
4.  Positive Output Connection Socket
5.  Negative Output Connection
6.  Remote Controller Plug
7.  Gas Output Connector
8.  AC/DC Selection Switch
9.  Welding Mode Selection Button
10. 2T / 4T Selection Switch

REAR PANEL

11. 240V AC Mains Power Switch
12. Gas Inlet Connector
13. Cooling Fan
14. 15 Amp Input Plug

3

4

10

9

8

2

1

5

13

6

11

7

12

14

DO NOT GRIND YOUR PLUG

This will void any warranty

on your machine

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Summary of Contents for TS200

Page 1: ...INVERTER AC DC TIG STICK WELDER MANUAL TS200 2 YEAR LIMITED WARRANTY ...

Page 2: ...enance small projects automotive repairs METAL TYPES Mild steel stainless steel aluminium S STICK Easiest process to learn Best choice for quick repairs Slower than MIG welding Forgiving in dirty rusty environments Not recommended for thin sheet metal welding METAL TYPES Mild steel stainless steel cast iron T TIG Gives a better weld finish Accurate heat control Considered the most challenging proc...

Page 3: ...C DC WELDING 14 GENERAL PULSE WELDING 15 GENERAL 2T 4T TRIGGER CONTROL 16 GENERAL LIFT ARC HF START 16 17 CURRENT REMOTE 17 CONTROL UPGRADE OPTIONS STICK MMA WELDING SETUP 18 19 ELECTRODE CURRENT SELECTION 20 GENERAL MMA WELDING 21 STICK MMA WELDING SETUP 19 20 GENERAL MMA WELDING 21 TIG WELDING SETUP 22 23 AC DC WELD CYCLE SETUP 24 25 TUNGSTEN PREPARATION 26 GENERAL TIG WELDING 26 27 17 TIG TORCH...

Page 4: ...ch 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 m...

Page 5: ... 1 TS200 AC DC Inverter TIG MMA Welder 2 4m 17 Series Tig Torch 3 Electrode Holder Lead 4 Welding Earth Lead 5 Gas Hose 6 Carry Strap 7 Dual Stage Argon Regulator 8 Torch Spares not shown 9 Cable Lead tidy not shown 10 Owners Manual not shown 1 2 3 4 5 7 6 ...

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: ...ing 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 instructions before using this welder Persons who are not familiar with this user guide should not use this welder Keep this booklet in a safe place for future reference TRAINING The o...

Page 8: ... must not touch the weld or the work piece unless wearing welding gloves Always use pliers or tongs Never touch the welded material with bare hands until it has completely cooled VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES Working with more than one welding machine on a single work piece or on work pieces that are connected may generate a dangerous accumulation of no load voltage between two diff...

Page 9: ...f BOSSWELD will not be liable or responsible for the loss of any gas DUTY CYCLE Special note If this welders duty cycle is exceeded the welder will enter thermal overload which will automatically stop the welding output in order to protect both the user and the welder You will know the welder has gone into thermal overload when the overload error indicator light is illuminated The welder will then...

Page 10: ...ve Output Connection 6 Remote Controller Plug 7 Gas Output Connector 8 AC DC Selection Switch 9 Welding Mode Selection Button 10 2T 4T Selection Switch REAR PANEL 11 240V AC Mains Power Switch 12 Gas Inlet Connector 13 Cooling Fan 14 15 Amp Input Plug 3 4 10 9 8 2 1 5 13 6 11 7 12 14 DO NOT GRIND YOUR PLUG This will void any warranty on your machine ...

Page 11: ...urn to adjust selected parameter the selected parameter will be illuminated 19 LCD Display panel On or off 20 Illuminates when Seconds is displayed on LCD panel 21 Illuminates when Percentage is displayed on LCD panel 22 Illuminates when Hertz is displayed on LCD panel 23 Illuminates when Amps is displayed on LCD panel 24 Illuminates when Volts is displayed on LCD panel 25 Overload Indicator Light...

Page 12: ...ent 4T Amps DC 10 170 AC 10 200 3 Upslope Time Seconds 1 0 10 0 4 Welding Peak Current Amps TIG DC 10 170 TIG AC 10 200 MMA DC 10 200 MMA AC 10 200 5 No Pulse Weld On or off 6 Pulse Weld On or off 7 Welding Base Current Amps TIG DC 10 170 TIG AC 10 200 MMA DC 10 200 MMA AC 10 200 8 Ratio of pulse Duration to Base Current Duration 5 95 9 Pulse Frequency Hz 0 5 200 10 Downslope Time Seconds 0 10 11 ...

Page 13: ...in shipbuilding because the current settings can often be higher than those used in DC welding and a deeper penetration of plate metals can be obtained The biggest drawback to using AC welding is the quality of the weld It is not as smooth as DC welding because of the continuous change in directional flow and there is likely to be more spatter Applications of DC Welding Welding with DC is best use...

Page 14: ...especially thin By pulsing along the weld joint you can moderate the amount of filler metal you add so that it s evenly distributed and you create a great looking weld Minimal Movement If you re in a tight spot and you don t have a lot of room to maneuver pulsing your TIG welder is one way to glide along the weld joint adding filler metal as you go without worrying about introducing too much heat ...

Page 15: ...amperage selected on the amperage dial 4 When you want to finish the weld press 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 5 Once you have released the trigger the arc will stop and the postflow gas will continue for a pre set amount of time LIFT ARC START With a ...

Page 16: ...t No 95 26F 4 1 CC12A The Bossweld 26 series TIG torch provides the operator with maximum versatility and maneuverability The 26series models provide simple on off gas switching capabilities and amperage control Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece 1 Press the button on the TIG torch 2 The Arc will start forming an arc between ...

Page 17: ...mp makes good contact with bare metal Take electrode holder and press handle to open the tong Insert bare metal rod end of electrode and release handle to clamp electrode 3 4 Assemble Arc and Earth leads into the welding terminals depending on requirements of electrodes Refer to your electrode packet for polarity and current requirements DCEP Negative Polarity most common application Earth clamp c...

Page 18: ...esired welding wave form AC or DC using the AC DC Selection switch MACHINE SET UP STICK MMA CONTINUED 5 6 7 Select your required amperage by turning the Multi Function Control knob You can adjust the Hot Start by pressing the Multi Function Control knob to cycle to Hot start then adjusting to the required parameter You can adjust the Arc force by pressing the Multi Function Control knob to cycle t...

Page 19: ... electrode will require about 40 Amps per millimeter diameter Therefore the preferred current level for a 4mm diameter electrode would be 160 Amps but the acceptable operating range is 140 to 180 Amps It is important to match the machine to the job Average Metal Thickness Electrode Size 1 0 2 0mm 2 0mm 2 0 5 0mm 2 6mm 5 0 8mm 3 2mm 8 0mm 4 0mm ELECTRODE SIZE SELECTION Electrode size selection will...

Page 20: ... example if welding Mild Steel then select a Mild Steel General Purpose Electrode Electrodes are identified by a universal numbering system AWS Type code Electrodes are often packed in sealed packaging to keep moisture out However if a pack has been opened or damaged it is essential that the electrodes are redried according to the manufacturer s instructions ARC FORCE Also called Dig and Arc Contr...

Page 21: ...ch head and ensure back cap and collet body are screwed in firmly WARNING CHECK ALL PARTS OF THE TIG TORCH FOR DAMAGE BEFORE USE ELECTRIC CURRENT CAN BE DANGEROUS 3 Plug the machine 15Amp input power plug into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Connect the Argon Gas Regulator supplied to the Gas bottle and connect the Gas Hose to the Gas Input so...

Page 22: ...t AC or DC welding AC DC Selection Switch figure 3 15 Fit the Earth lead Dinse Plug to the positive terminal for gasless welding and then connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal Set remaining parameters referring to the table on page 24 to 26 Please note not all parameters are relevant to DC TIG welding Switch the machine on using the mains ...

Page 23: ... Selection for Pulse or No Pulse Base Current only when Pulse is Selected Selection for the Base Welding Amperage required during welding Downslope Selection for the transition time from Peak Amperage to Finish Amperage Crater Arc Current Selection for the amount of fill at the end of the weld Post Gas Selection for gas flow time after the arc finishes AC WELDING ONLY Balance Selection to adjust t...

Page 24: ...uired parameter Amps DC 10 170 AC 10 200 Pressing the Multi Function Control knob to cycle to Pulse Function you can either select No Pulse or Pulse the digital scree will display like below NO PULSE PULSE Pressing the Multi Function Control knob to cycle to Upslope then adjusting to the required parameter 1 0 10 0 Seconds NOTE STEPS 6 to 8 ONLY VALID IF PULSE IS SELECTED Pressing the Multi Functi...

Page 25: ...ol knob to cycle to Post gas then adjusting to the required parameter 1 0 10 0 Seconds Pressing the Multi Function Control knob to cycle to Frequency then adjusting to the required parameter Hz 0 5 200 NOTE THIS STEP IS ONLY VALID IN AC WELDING Pressing the Multi Function Control knob to cycle to Balance then adjusting to the required parameter 5 5 Pressing the Multi Function Control knob to cycle...

Page 26: ...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 27: ...rial 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 in mechanise...

Page 28: ...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 Lens Collet 3 2mm 954...

Page 29: ...9 1 6mm 1Kg 300054H Bossweld 309 2 4mm 1Kg 300055H Bossweld 316L 1 2mm 1Kg 300066H Bossweld 316L 1 6mm 1Kg 300067H Bossweld 316L 2 4mm 1Kg 300068H Bossweld 316L 3 2mm 1Kg 300069H Bossweld 347 1 6mm 1Kg 300071H Bossweld 347 2 4mm 1Kg 300072H Bossweld 5356 2 4mm 1Kg 300009H Bossweld 5356 3 2mm 1Kg 300010H Bossweld 4043 1 6mm 1Kg 300015H Bossweld 4043 2 4mm 1Kg 300016H Bossweld 4043 3 2mm 1Kg 300017H...

Page 30: ... into the 240V mains outlet and is switched on Check that the mains fuse or breaker has not operated Check that the main switch on the rear of the unit is in the on 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...

Page 31: ...g technique Select a lower voltage range Material too thick Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics Keep the arc at the leading edge of the weld pool and maintain the gun angle at 5 15 keeping the stick out between 5 10mm Select a higher voltage range and Remove materials like paint grease oil an...

Page 32: ... 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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