MODEL • • BOSS ARC 140VRD BOSS ARC 160VRD Operating Manual (Owner’ s Manual) IMPORTANT: Read these instructions before installing, operating, or servicing this system. First Edition September, 2008 Manual No.
CONTENTS SYMBOL LEGEND---------------------------------------------------------------------------------------------------2 STATEMENT OF WARRANTY------------------------------------------------------------------------------------3 1.0 GENERAL INFORMATION-------------------------------------------------------------------------------4 1.01 Notes, Cautions and Warnings------------------------------------------------------------------------4 1.
SYMBOL LEGEND A V Hz Amperage Stick (SMAW) Voltage Pulse Current Function (GTAW) Hertz (frequency) Spot Time (GTAW) t SEC Seconds Remote outputs control (Panel/Remote) % Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current) Gas Post-Flow Time t2 2T (GTAW) Gas Pre-Flow Time t1 VRD 4T (GTAW) — Repeat Function (GTAW) + Spot Function (GTAW) Voltage Reduction Device Circuit Negative Positive High Frequency Starting (GTAW) Gas Input Lift Start （GTAW
STATEMENT OF WARRANTY LIMITED WARRANTY: "BOSS" warrants to customers of its authorized distributors hereafter "BOSS" that its products will be free of defects in workmanship or material.
1.0 GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.
ELECTRIC SHOCK Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. l Never touch any parts that are electrically “live”or “hot.” l Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. l Repair or replace all worn or damaged parts. l Extra care must be taken when the workplace is moist or damp.
1.03 Transporting methods These units are equipped with a handle for carrying purposes. WARNING: ELECTRIC SHOCK can kill. DO NOT TOUCH live 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 l l Lift unit with handle on top of case. Use handcart or similar device of adequate capacity.
2.0 INSTALLATION RECOMMENDATION Installation Environment BOSS ARC VRD Series is designed for use in hazardous environments.
2.01 Electrical Input Connections WARNING: ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts SHUT DOWN welding power source, disconnect input power employing lockout/ tagging procedures. Lockout/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
2.02 Specifications MODEL BOSS ARC 140VRD BOSS ARC 160VRD Input voltage and frequency and phases 220/240V 50/60Hz 1ph 220/240V 50/60Hz 1ph TIG 4.3KVA 4.8KVA STICK 6.0KVA 7.4kVA Max current 140A 160A Output current range 10~140A 10~160A Open circuit voltage 56/61V 56/61V Duty cycle at 40℃ 60% 60% Weight 9.5kg 12kg Dimensions (mm) 370×150×245 420×160×265 KVA @ max output Table 3 2.
3.0 OPERATOR CONTROLS 3.01 BOSS ARC VRD Series Controls Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Welding Current Control— — Used for regulating to welding current. Warning Indicator AC Power Indicator Main Power Switch Positive (+) Socket— — TIG connect the work lead/ MMA connect the electrode holder. Negative (-) Socket— — TIG connect the TIG torch/ MMA connect the work lead.
3.02 Weld parameters description Figure 3 BOSS ARC VRD Series front panel with parameter description Parameter Welding Current Description This parameter sets the welding current.
4.0 SET-UP FOR MMA (STICK) AND GTAW (TIG) Conventional operating procedures apply when using the welding power source, i.e. connect work lead directly to work piece and welding cable is used to electrode holder. Wide safety margins provided by the coil design ensure that the welding power source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only.
4.01 Stick welding l l l l Connect work lead to negative terminal. Connect electrode lead to positive terminal. Switch machine on. Set welding current control (see table 5). Workpiece thickness mm 0.5-2.0 2.0-5.0 5.0-7.0 Electrode diameter mm 1.0-2.0 2.0-3.2 3.2-4.0 Welding current（A） 10-50 50-150 150-250 Table 5 4.02 DC TIG welding l l l l l Connect work lead to positive terminal. Connect TIG torch to negative terminal. Switch machine on. Set welding current control (see table 6).
5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES Figure 5 1. 2. 3. 4. BOSS ARC VRD Series front panel Welding currents control— — Uses in adjusting the welding current. VRD indicator. Warning indicator— — Red colored light instruction welding machine overload. AC power indicator— — Green colored light instruction power source is normal.
6.0 BASIC TIG WELDING GUIDE 6.01 Electrode Polarity Connect the TIG torch to the - / torch terminal and the work lead to the + / work terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. 6.02 Tungsten Electrode Current Ranges Electrode Diameter (mm) DC current (A) 1.0 30— 60 1.6 60— 115 2.4 100— 165 3.2 135— 200 4.
6.05 Shielding gas selection Alloy Shielding gas Aluminium & alloys Argon Carbon steel Argon Stainless steel Argon Nickel alloy Argon Copper Argon Titanium Argon Table 10 6.06 Shield gas selection TIG welding parameters for low carbon & low alloy steel pipe Tungsten type & diameter Current range DC (Amperes) Filler rod for root pass Thoriated 2% 3/32”(2.4mm) 120— 170 Yes Thoriated 2% 3/32”(2.4mm) 100— 160 Yes Thoriated 2% 3/32”(2.4mm) 90— 130 No Table 11 6.
7.0 BASIC ARC WELDING GUIDE 7.01 Electrode polarity Stick electrodes are generally connected to the “+”terminal and the work lend to the “-“terminal but if in doubt consult the electrode manufacturers literature. 7.02 Effects of stick welding various materials High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks.
8.0 MAINTENANCE If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical work must be performed by an electrician or other person properly trained in servicing electrical equipment. Do not permit untrained persons to inspect, clean or repair this equipment. Use only recommended replacement parts when servicing this machine.
9.0 BASIC TROUBLESHOOTING WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an accredited BOSS service agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the welding power source must be returned to an accredited BOSS service agent for repair.
9.02 TIG welding problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique. Description 1. Excessive bead build-up or poor penetration or poor fusion at edges of weld. 2. Weld bead too wide and flat or undercut at edges of weld or excessive burn through. 3. Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart. 4.
11. Arc start is not smooth. A Tungsten electrode is too large for A Select the right size electrode. the welding current. Refer to basic TIG welding guide. B The wrong electrode is being used B Select the right electrode type. for the welding job. Refer to basic TIG welding guide C Gas flow rate is too high. C Select the correct rate for the welding job. D Incorrect shielding gas is being D Select the right shielding gas. used. Refer to Basic TIG Welding Guide.
9.04 Power source problems Description Possible Cause Remedy 1 The welding arc can not be established. A The Primary supply voltage has not A Switch on the primary been switched on. supply voltage. B The welding power source switch is B Switch on the welding switched off. power source. C Loose connections internally. C Have an accredited BOSS service agent repair the connection. 2 Maximum output welding current can not be achieved with nominal Mains supply voltage. Defective control circuit.
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- 24 BOSS ARC 140VRD、160VRD Operating Manual
Figure 6 QTY. Sequence Order No Name ARC 140VRD ARC 160VRD Sensor A Sensor B Sensor A Sensor B 1 3KITP000505020 BOARD,PCB,CONTROL (7.820.514-09) 1 3KITP000502002 BOARD,PCB,CONTROL 2 3KITP000106101 OUTPUT MMA160H 2 2 1 (7.820.514-10) 1 1 1 1 OUTPUT MMA160H(SENSOR) 3KITP000106000 2 OUTPUT MMA140 1 1 OUTPUT MMA140 (SENSOR) 2-1 3KITP000506011 BOARD,PCB,MOSFET (7.820.005B) 2-1 3KITP000106011 BOARD,PCB,MOSFET (7.820.016A) 2-2 3KITP000506021 BOARD,PCB,DIODE (7.820.
2-9 2-10 2-11 3KITP000106030 THERMOSTAT (Inside) 4VQK2SK2837 MOSFET 2837 1 1 1 12 12 16 16 12 12 16 16 2-12 4LZQ4X2X5 HOSE FERRITE 4*2*5 36 36 48 48 2-13 2FP8647002 INSULATOR II 16 16 20 20 2-14 2FP8647003 INSULATOR I 1 1 1 1 2-15 2FPBM8610016 BRACKET,HEATSINK MOUNTING 1 1 2-16 2FPBM8610017 BRACKET,HEATSINK MOUNTING 1 1 2-17 2FPBM8610021 BRACKET,HEATSINK MOUNTING I 2 2 2-18 2FPBM8610022 BRACKET,HEATSINK MOUNTING II 2 2 2-15 2FPBM8610000 BRACKET,HEAT
30 4FANCA1238 FAN COVER 1 1 1 1 31 2FP8647000-1 CAP PROTECTION (Inside) 2 2 2 2 32 4JFT20X27 MOUNT NPRN JJ30 4 4 4 4 33 4FAN001SA1238 FAN 1 1 1 1 34 2PST8634001 INSULATOR FAN 1 1 1 1 36 481CC2KV103 CAPACITOR 3KV103 1 1 1 1 4V2FDLEDD5GN LED GN 2 2 2 2 4V2FDLEDS01D5 LED BASE 2 2 2 2 4V2FDLEDD5RDGN LED RD/GN 2 2 2 2 38 39 4V2FDLEDD5X7 LED BASE 2 2 2 2 40 4WTH1A2W1K POTENTIONMETER 2W 1K 1 1 1 1 44 2FPPC8041109 PANEL CONTROL ARC 140VRD F
