BossWeld X Series Page 2 Manual Download | Manualshive

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Thank you for choosing a BOSSWELD MST 200 X4 AC/DC Multi Process Inverter Welder

In this manual you will find instructions on how to set up your welder along with general welding information,
safety information and helpful tips. We encourage you to go online to our website for more tips and trouble-
shooting as well as many welding resources.
The BOSSWELD MST 200 X4 is the latest in IGBT multipurpose welder technology, this very portable power
source enables the user to complete high quality welds in both MIG - TIG - MMA/Stick electrode applications.
This welder is easy to set up, easy to use and will provide very smooth output.
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 pool

• Gas or flux prevents oxidisation in the weld

• Weld with or without gas

• Point and pull the trigger

• Great for maintenance, 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 process to learn

• Good way to weld thin material

• Argon gas is required

METAL TYPES

Mild steel, stainless steel & aluminium

P

PLASMA CUTTING

P

• Wide range of uses to cut conductive metals

• Uses an accelerated jet of hot plasma

• High speed/low cost cutting method

• Used extensively replacing gas cutting methods

• Air compressor is required

METAL TYPES

Mild steel, stainless steel & aluminium

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Summary of Contents for X Series

Page 1: ...AC DC MULTI PROCESS INVERTER WELDER 240V MANUAL ...

Page 2: ... 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 projects automotive repairs M...

Page 3: ...OR WELDING WITH MST 200X4 27 TIG SETUP 28 31 LIFT ARC START AND HR ARC START 32 TUNGSTEN PREPARATION GRINDING AND FOOT CONTROL OPTION 33 BASIC TIG WELDING GUIDE 34 AC DC WELDING 34 35 PULSE TIG WELDING 36 STICK AC DC SETUP 37 38 GENERAL MMA WELDING GUIDE 39 SET UP OF WIRE SPOOL WIRE FEED UNIT 40 MIG TORCH SETUP 41 MACHINE DRIVE ROLLER SIZE GUIDE 41 MIG TORCH LINER INSTALLATION REPLACEMENT 42 MIG T...

Page 4: ...ders 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 website www bossweld com au warranty 2 TIME PERIOD 3 Years A warranty claim must be made within 3 years from the date of purchase of this product Any claim must include proof of purchase 3 HOW TO MAKE A CLAIM NEED SOME HE...

Page 5: ...eries MIG Torch 3 4 metre 17 Series TIG Torch 4 3 metre welding cable with electrode holder 5 3 metre earth cable with earth clamp 6 2 metre quick connect gas hose 7 Dual stage Argon regulator 8 Spanner 9 0 8 0 9mm V groove drive rollers Fitted 0 8 0 9mm Knurled drive roller Spare 10 Operating manual not shown Note Pictures may vary from your machine model 5 9 ...

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: ...ection Socket 3 MIG Torch Euro Connector 4 Control Socket 5 Polarity Switching Cable 6 TIG Torch Gas Connector 7 Negative Output Connection Socket REAR PANEL 8 Power Switch 9 Input Power Cable 10 Cooling Fan 11 Gas Inlet Connector 8 1 5 9 10 11 6 7 2 3 4 ...

Page 11: ...urge to gas lines 6 Manual wire feed button 7 L parameter knob Press to select parameters and rotate to adjust values such as weld ing current In function interface rotate to select parameters 8 Function button Press to select parameters or enter the function interface 9 R parameter knob Press to select parameters and rotate to adjust values 7 8 9 1 4 5 6 2 3 SIDE PANEL DOOR OPEN A Spool Hub B Spo...

Page 12: ...dered grounds for warranty or return The term duty cycle indicates 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 MIG SETTINGS SHOW BELOW Amps refer to the Current setting 10 60 100 200 Amps 85 Amps 65 Amps 24 0 Volts 18 3 Volts 17 3 Volts For example...

Page 13: ... polarity switching cable to the terminal 5 Connect earth clamp to the terminal Roller Groove V Groove Mild Steel U Groove Aluminium V knurled Gasless Wire Drive roller size mm Plug the machine 10Amp input power lead into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Open wire feed side panel and install GAS wire into machine ensuring the drive roller is ma...

Page 14: ... 0mm Ar 100 Copper Silicon Cusi3 Ar 100 Press Synergic button and adjust knob to select wire material wire diameter type of gas Press knob to confirm 10 Ar 100 80 Ar 20 CO2 CO2 98 Ar 2 CO2 Fit the Earth lead Dinse Plug to the negative terminal for gas welding and then connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal 5 Fit gas regulator to the gas bot...

Page 15: ...w time prior to the arc starting 4 Post Flow 0 1s 10s Selection for gas flow time after the arc finishes 5 Slow Feed 0 10 Selection for wire feed speed before arc start Machine is ready to weld at optimum setting If the welder is running too hot adjusting the left knob back a little will also adjust the wire feed speed and Amps all in Synergy with each other 15 Rotate right knob to trim the weldin...

Page 16: ...DCEN GASLESS DCEP GAS SETTING MACHINE POLARITY 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 Install Euro connect MIG torch over the protruding wire line ...

Page 17: ...sing the trigger again 12 Fit the Earth lead Dinse Plug to the negative terminal for gas welding and then connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal 5 Turn on regulator and set gas flow to between 10 15 L min depending on your welding environment 7 Fit gas regulator to the gas bottle and install gas hose to the gas inlet on the back panel of we...

Page 18: ...T and 4T 2 Burnback 0 10 Selection for the amount of wire to burn back after release the torch trigger 3 Pre Flow 0 1s 5s Selection for gas flow time prior to the arc starting 4 Post Flow 0 1s 10s Selection for gas flow time after the arc finishes 5 Slow Feed 0 10 Selection for wire feed speed when welding Rotate left knob to adjust wire feeding speed Rotate right knob to adjust welding voltage Pr...

Page 19: ...s plug into negative output connection socket for gasless welding 5 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 6 Continue from MIG manual GAS set up page 17 step 9 to 14 8 Note It is advisable to run a few test welds using scrap or offcut materials in order to t...

Page 20: ...ylinder 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 2 Connect Spool Gun to the Euro Connection terminal NOTE Ensure connector nut is tighten firmly 3 Connect earth Clamp to the terminal 14 Select MIG Manual mode 3 Connect polarity switching cable to the terminal 5 6 Fit gas regulator to bot...

Page 21: ...ease the wire tensioning arm and check the correct drive roller size matches the wire being used 9 TOP VIEW Re latch the tensioning arm making sure you still hold the spool to stop it unraveling Screw in to increase tension 11 TOP VIEW Connect earth clamp to the work piece ensuring that the clamp makes good contact with bare metal 4 Turn on regulator and set gas flow to between 10 15 L min dependi...

Page 22: ... for the amount of wire to burn back after release the torch trigger 3 Pre Flow 0 1s 5s Selection for gas flow time prior to the arc starting 4 Post Flow 0 1s 10s Selection for gas flow time after the arc finishes 5 Slow Feed 0 10 Selection for wire feed speed when welding 6 Spool Gun ON or OFF Switch for Spool Gun Press 2T 4T button to select 2T or 4T mode 2T Mode Press the gun torch trigger to w...

Page 23: ...the machine 10Amp input power lead into the wall socket ensuring that the power switch on the machine is in the OFF position 1 Install the Spool Gun to the machine by connecting Euro Connector and the Control Socket and screw the nut up firmly 3 Ensure the polarity switching cable is plug into negative output connection socket for gasless welding 2 MIG MANUAL SPOOL GUN SET UP GASLESS Fit the Earth...

Page 24: ...e current level A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the wire diameter and thickness of the material being welded If the wire speed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool If the wire speed is too slow for the welding voltage large drops will form on the end of the electro...

Page 25: ...e arc at the wire tip and filler metal for the joint The wire is fed through a copper contact tube contact tip which conducts welding current into the wire The weld pool is protected from the surrounding atmosphere by a shielding gas fed through a nozzle surrounding the wire Shielding gas selection depends on the material being welded and the application The wire is fed from a reel by a motor driv...

Page 26: ...normally 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...

Page 27: ...2 24 4 11 2 22 4 13 3 23 0 16 0 21 0 6 0mm 14 2 23 7 12 5 23 2 8 0mm Material Thickness Steel DC Solid 80 Argon 20 CO2 100 CO2 Ø 0 6mm Ø 0 8mm Ø 0 9mm Ø 1 0mm Ø 0 8mm Ø 0 9mm Ø 1 0mm m min V m min V m min V m min V m min V m min V m min V 0 8mm 5 5 14 0 3 0 14 5 1 0mm 6 7 14 8 3 6 15 0 2 9 14 3 3 4 16 0 3 5 17 0 1 2mm 8 1 15 3 4 4 15 6 3 7 14 8 14 0 14 0 3 8 16 5 4 1 17 7 3 0 16 5 1 6mm 9 5 17 0 5...

Page 28: ...tall the TIG Torch to the machine by connecting the Dinse Connector to the Negative Output Connection Socket the Gas hose to the Gas Output and the TIG Torch Control Socket and screw the nut up firmly Set up the TIG torch Ensure collect body collet with back cap are screw in firmly 3 Place the Tungsten Electrode into the torch head then screw in alumina cap 4 2 5 Connect earth Clamp to the termina...

Page 29: ...he tungsten electrode near the job and simply press the torch trigger to start the arc Ref Lift Arc Start and HF Arc Start Guide on page 32 10 Press 2T 4T button to select 2T or 4T mode 2T Mode Press the gun torch trigger to weld and release to stop 4T Mode Press and release the gun torch trigger to start weld without holding the trigger on and stop by pressing and releasing the trigger again 9 IM...

Page 30: ...inish Amperage 12 Post Current 10A 200A Selection for the amount of amps required at the end of the weld 13 Post Flow 0s 10s Selection for gas flow time after the arc finishes For NO Pulse Welding To adjust functions press parameter button rotate left knob for function selection and rotate right knob for adjustment then press parameter button again for confirmation Ref Pulse TIG Welding Guide on p...

Page 31: ...band Ref AC DC Welding Guide on page 34 35 For Spot Welding Spot welding is quick and easy and creates a strong join It doesn t use any flux or filler metal so there is no need to grind excess slag when finished and there is no dangerous open flame It can only create localized joins and can be challenging to join oddly shaped pieces of metal To adjust functions press parameter button rotate left k...

Page 32: ...C START Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece 1 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 3 Press the button on the TIG torch 2 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 4 HF ARC START Note Pict...

Page 33: ...ANDER TUNGSTEN ELECTRODE GAS LENS STABLE ARC FLAT TIP POINTED TIP GRINDING WHEEL GRINDING WHEEL FILLER WIRE Note Do not use wheel for other jobs or tugsten can become contaminated and cause lower weld quality FOOT CONTROL OPTIONS Bossweld Foot Control 3mt Part No 660201 3 metre cord Ideal for bench work Parent Child relationship between the welder and foot controller This means if you set the weld...

Page 34: ...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 WELDING GAS SELECTION CHART GUIDE T TIG X X X X X X X X TIG WELDING MILD STEEL STAINLESS STEEL LOW ALLOY STEEL ALUMINIUM ARGON Ar CO2 O2 FLUX COATING ROD ARC WORK PIECE WORK PIECE WORK PIECE WORK PIECE WORK...

Page 35: ...s being welded magnetic vs non magnetic Proper edge preparation the cleaner the edge the better the weld Current settings DC vs AC Speed of travel the angle of the electrode needs to be maintained throughout the length of the joint as it is being welded A strong weld can be achieved in both AC welding and DC welding so long as you weld with the current and polarity appropriate for the material bei...

Page 36: ...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 37: ...cket for polarity and current requirements DCEP Electrode connected to Positive output socket DCEN Electrode connected to Negative output socket 2 Connect earth clamp firmly to work piece ensuring that the clamp makes good contact with bare metal 3 Take electrode holder and insert bare metal rod end of electrode and twist red handle to clamp electrode 4 OFF Plug the machine 10Amp input power lead ...

Page 38: ...orce adjustment the higher the minimum voltage that the power source will allow This effect will also cause the welding current to increase 5 8 Please see table on page 39 as a guide to Welding Parameters 9 Amperage Selection Guide Rod Size Gauge Welding Current 1 6mm 40 50 Amps 2 0mm 50 75 Amps 2 5mm 75 105 Amps 3 2mm 105 140 Amps 4 0mm 140 160 Amps Average Metal Thickness Electrode Size 1 0 2 0m...

Page 39: ...ck 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 Control Gives a power source variable additional amperage during 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...

Page 40: ...ting Then replace the Drive Roller Cover See Page 41 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 Note Pictures may vary from your machine model Ensure you hold the spool and check tension to stop wire spool unraveling Roller Groove V Groove Mild Steel U Groove Aluminium V knurled Gasless Wire Drive r...

Page 41: ...r For Gasless Wire RK302210 08 10 Drive Roller 0 8 1 0mm Knurled 30 x 22 x 10mm RK302210 09 12 Drive Roller 0 9 1 2mm Knurled 30 x 22 x 10mm RK302210 10 12 Drive Roller 1 0 1 2mm Knurled 30 x 22 x 10mm U Grooved Drive Roller For Aluminium Wire RU302210 06 08 Drive Roller 0 6 0 8mm U Groove 30 x 22 x 10mm RU302210 08 09 Drive Roller 0 8 0 9mm U Groove 30 x 22 x 10mm RU302210 08 10 Drive Roller 0 8 ...

Page 42: ...ut up all the way Carefully 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 43: ... 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 44: ...rch fault when switch on the machine E23 Torch fault during normal working process Accessory E30 Cutting torch disconnection E31 N A Communication E40 Connection problem between wire feeder and power source E41 Communication error JOB PROGRAM DISPLAY INTRODUCTION 1 JOB button Press it for 3s to enter JOB programs and press it for 1s to save parameters Can t save when all slots are in used 2 Parame...

Page 45: ...e with screws N A 92 09 BWT Trigger N A M6 Standard Duty M6 Heavy Duty M6 Aluminium 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 Contact tip 0 9mm x M6 x 6mm dia x 25mm long 140 0177 92 01 15 10 Contact tip 1 0mm x M6 x 6mm dia x 25mm long 140 0253 92 01 25 06 Contact...

Page 46: ...ION 95 17F 4 1 SW9A Bossweld 17 Series TIG Torch 4mt 9 pin Plug 95 17F 8 1 SW9A Bossweld 17 Series TIG Torch 8mt 9 pin Plug 95 26F 4 1 SW9A Bossweld 26 Series TIG Torch 4mt 9 pin Plug 95 26F 8 1 SW9A Bossweld 26 Series TIG Torch 8mt 9 pin Plug PART NO DESCRIPTION 9957Y04 Back Cap Short 9557Y05 Back Cap Medium 955Y02 Back Cap Long PART NO DESCRIPTION 9518CG Torch Body Front Insulator 9554N01 Torch ...

Page 47: ...25 06 Contact Tip heavy duty 0 6mm x M6 x 8mm dia x 25mm long 92 01 25 08 Contact Tip heavy duty 0 8mm x M6 x 8mm dia x 25mm long 92 01 25 09 Contact Tip heavy duty 0 9mm x M6 x 8mm dia x 25mm long 92 01 25 10 Contact Tip heavy duty 1 0mm x M6 x 8mm dia x 25mm long 5 92 02 15 10 Adjustable tapered nozzle ø 10mm 6 92 02 15 CO Adjustable conical nozzle ø 12 mm 7 92 02 15 CL Adjustable cylindrical no...

Page 48: ...s normal Produces smoke and splatters It is important that correct drive roller is used to get the best results V groove Roller Roller has a small V shaped groove to guide the wire V Knurled roller assists in gripping as wire is soft U groove Roller assist in gripping as wire is softest Machine can be used in both DC and DC modes earth earth 3m only for push torch Teflon liner U groove roller allo...

Page 49: ... 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 50: ...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 51: ...ace the O Ring 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 we...

Page 52: ...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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