Boss MIG 165 Operating Manual Download

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MODEL

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BOSS Inverter MIG 165

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BOSS Inverter MIG 200

Operating Manual

(Owner’s Manual)

IMPORTANT: Read these instructions before installing, operating, or servicing this system.

First Edition
September, 2008 Manual No. B0804

Summary of Contents for MIG 165

Page 1: ...BOSS Inverter MIG 165 BOSS Inverter MIG 200 Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system First Edition September 2008 Manual No B0804 ...

Page 2: ...s 11 3 02 INVERTER MIG Series Control Methods 13 3 03 Weld Parameter Description 13 4 0 SET UP FOR MIG MAG 14 5 0 POWER SUPPLY CONTROLS INDICATORS AND REATURES 15 5 01 Basic MIG Welding Guide 16 5 02 Position of MIG GUN 16 5 03 Distance from the MIG Gun Nozzle to the Work Piece 16 5 04 Travel Speed 16 5 05 Electrode Wire Size Selection 16 5 06 Spot Welding Operation 17 6 0 MAINTENANCE 18 7 0 BASIC...

Page 3: ...TAW SEC Seconds Remote outputs control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current t2 Gas Post Flow Time 2T GTAW t1 Gas Pre Flow Time 4T GTAW VRD Voltage Reduction Device Circuit Repeat Function GTAW Negative Spot Function GTAW Positive High Frequency Starting GTAW Gas Input Lift Start GTAW Gas Output ...

Page 4: ...ract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of BOSS is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN BOS...

Page 5: ...rocess can be dangerous and hazardous to your health l Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume l Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases l The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the different processes You must...

Page 6: ...gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table Do not cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed saf...

Page 7: ...electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage l Lift unit with handle on top of case l Use handcart or similar device of adequate capacity l If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 8: ...r vicinity of the operator which can cause increased hazard have been insulated Installation Location Be sure to locate the welder according to the following guidelines l In areas free from moisture and dust l In areas free from oil steam and corrosive gases l In areas not exposed to direct sunlight or rain l Ambient temperature between 10 degrees C to 40 degrees C l In areas not subjected to abno...

Page 9: ...voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power sup...

Page 10: ...roller required with the chosen wire size marking facing outwards l Fit the electrode wire spool to the wire reel hub l Lift up the wire feeder pressure lever and lift the electrode wire to the entrance of the gun l Lower the pressure lever and with the gun lead reasonably straight feed the wire through the gun till to extend from the hole in the middle of contact tip l Regulate the current voltag...

Page 11: ...damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal operating temperature Continually exceeding the duty cycle ratings can...

Page 12: ...14 Pin Receptacle Used to connect the wire feeder 5 Positive Terminal 50mm Screw receptacle 6 Negative Terminal 50mm Screw receptacle 7 Terminal Use to connect the torch 8 Selector Control 2T 4T 9 Inductance Control 10 Meter Selection 11 Digital Meter 12 Warning Indicator Activates under the following conditions Input voltage is too low too high Thermal overload 13 AC Power Indicator Lights when i...

Page 13: ...B Torch switch input Torch switch input C Current regulation D Current regulation E Current regulation F Short line Short line G Short line Short line H Short line I Spot switch J Spot switch K Solenoid valve L Solenoid valve M WF2 motor Spool gun motor N WF2 motor Spool gun motor Table 5 WARNING When the welder is connected to the primary supply voltage the internal electrical components maybe at...

Page 14: ...arameter description Figure 4 Inverter Mig series front panel with parameter description Parameter Description Welding Current This parameter sets the welding current Burnback Time MIG only Burnback time is the difference between the wire feed motor stopping and switching off of the welding current The Burnback time allows the electrode wire to burn out of the molten metal weld pool to separate th...

Page 15: ...arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for Inverter Mig series WARNING Before con...

Page 16: ...TURES Figure 6 Inverter Mig series front panel 1 Main Power Switch 2 Wire Feed Speed Control 3 Voltage Control 4 Selector Control 2T 4T 5 Inductance Control 6 Meter Selection 7 Voltage Indicator 8 Speed Indicator 9 Amperage Indicator 10 Digital Meter 11 Warning Indicator 12 AC Power Indicator ...

Page 17: ...wire diameter and dimensions of the work piece l 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 electrode wire causing spatter Suppose that wire speed is constant if the welding voltage is too high large drops will form on the end of the ele...

Page 18: ...her deposition rates therefore greater productivity will be achieved by using smaller electrode wire The Inverter Mig series is a particularity efficient MIG welder with the 0 9mm 1 2mm steel wire in spray transfer mode 0 9mm wire cost approx 10 more than 1 2mm but is deposited approx 15 faster High current density or smaller diameter wire also gives deeper penetration as shown Figure 8 Wire penet...

Page 19: ...s to the machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring of machine for loose or frayed connections tighten or repair as necessary It would also be advisable to check connections to wire feeders fixtures etc at this time Any damaged cable or hoses should be replaced DANGER HIGH VOLTAGE is present internally even with the control power switch...

Page 20: ...CB damage 1 Turn on the gas system 2 Repair or replace 3 Repair or replace 4 Repair or replace 4 Turn on torch control switch c Have gas flow Have wire feed No output 1 Disconnect the work piece to the work ground cable 2 Wire feed control PCB damage 1 Reconnect the ground cable and tighten the work piece 2 Repair or replace 5 Faulty welding arc control 1 The MIG torch damage 2 Faulty setting 3 Ma...

Page 21: ...upply l Internal gas hose in the power supply Ensure the hose from the solenoid valve to the MIG gun adaptor has not fractured and that it is connected to the MIG gun adaptor l Welding in a windy environment Shield the weld area from the wind or increase the gas flow l Welding dirty oily painted oxidized or greasy plate Clean contaminates off plate l Distance between the MIG gun Keep the distance ...

Page 22: ... feed roller groove shape or size Debris is fed into the liner where it accumulates thus reducing wire feed ability l Incorrect or worn contact tip The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip When using soft electrode wire such as ...

Page 23: ...tage by reducing wire speed control or increasing the voltage selection switches 5 Irregular weld shape A Incorrect voltage and current settings Convex voltage too low Concave voltage too high B Wire is wandering C Incorrect shielding gas D Insufficient or excessive heat input A Adjust voltage and current by adjusting the voltage selection switches and the wire speed control B Replace the contact ...

Page 24: ...ntact tip replace faulty components B Have an accredited BOSS service agent investigate the faulty 5 Wire feeds when the gun trigger switch is depressed but arc can not be established Poor or no work lead connection Clean work clamp area and ensure good electrical contact 6 Wire continues to feed when the gun trigger switch is released The mode selector switch has been set to 4T latch operation Se...

Page 25: ... 24 BOSS Inverter Mig 165 200 Operating Manual 8 0 PART LIST ...

Page 26: ... 25 BOSS Inverter Mig 165 200 Operating Manual Figure 9 ...

Page 27: ...Inside 2 2 2 16 2FPBM8610039 BRACKET HEATSINK MOUNTING I 4 4 2 17 2FPBM8610040 BRACKET HEATSINK MOUNTING II 2 2 2 18 2FPPP8610117 BRACKET MOSFET DIODE 8 610 117 15 15 2 19 2FPPP8610118 BRACKET MOSFET DIODE 8 610 118 Inside 2 2 2 20 2FP7840020 INSULATOR HEATSINK Inside 1 1 2FP7854011 SPACER NYLON 凹 D5 Inside 18 18 2 21 4BFTDQ001D5 SPACER NYLON 凸 D5 Inside 18 18 2FP7854012 SPACER NYLON 凹 D3 Inside 6...

Page 28: ...28 2LAW8805004 LABEL WARNING 1 1 29 2LAC8807053 LABEL BURNBACK 1 1 30 2FPB6123016 BASE 1 1 31 2FPBG6153001 PANEL CENTER 1 1 32 2FPUT8038029 PANEL UPPER TRAY 1 1 33 2FBM8604059 BRACKET DISPLAY B MOUNTING Inside 1 1 34 2FBM8604073 BRACKET 14 PIN MOUNTING Inside 1 1 35 2FP7854004 INSULATOR BULKHEAD FRONT 2 2 36 2FP7854008 INSULATOR BULKHEAD REAR 2 2 37 2GS50CC001FP RECEPTACLE TWIST LOCK FEMALE POWER ...

Page 29: ...chines rear panels meet the plume to have good to turn on the earth grounding by guarantees the welder safety When welder operation should wear protects the mirror the glove puts on protects the clothing 9 2 When the electrical network voltage is higher than 240V 260V the out put will appear the class the overload the welding machine automatically has stopped outputting and giving the red candle d...

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