MODEL • • • • BOSS BOSS BOSS BOSS MIG MIG MIG MIG 185 202 255 275 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 MIG 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.
(MIG 275) Figure 1 Electrical input connections 2.02 Installation of MIG/MAG l Connect the work lead to negative (-) socket (positive (+) for special wire). l Connect the gun lead to the positive (+) socket (negative (-) for special wire). l Position a gas cylinder on the rear tray and lock securely to the power supply cylinder bracket with the chain provided.
2.03 Specifications MODEL Input voltage and frequency and phases KVA @ max output BOSS MIG 185 BOSS MIG 202 220/240V 50/60Hz 220/240V 50/60Hz BOSS MIG 255 BOSS MIG 275 220/240V 50/60Hz 415V 50/60Hz 6.6KVA 8.0kVA 11.8kVA 12kVA Input Current 30A 36.7A 53.4A 16.
Wire Size Idle Roll ×1 WF 82E Drive Roll ×1 2WZKIDLE001 0.6/0.8mm 2WZKVY0R6X0R8 2WZKKVY0R6X0R8 2WZKUL0R6X0R8 0.8/1.0mm 2WZKVY0R8X1R0 2WZKKVY0R8X1R0 2WZKUL0R8X1R0 0.9/1.2mm 2WZKVY0R9X1R2 2WZKKVY0R9X1R2 2WZKUL0R9X1R2 1.0/1.2mm 2WZKVY1R0X1R2 2WZKKVY1R0X1R2 2WZKUL1R0X1R2 2WZKKVY1R2X1R2 1.2/1.2mm Table 5 2.
3.0 OPERATOR CONTROLS 3.01 BOSS MIG Controls Figure 2 1. Main Power Switch. 2. Wire Speed Control. 3. Spot Time Control. 4. Mode Selector Switch 2T/ Spot/ 4T. 5. 14 Pin Receptacle. 6. Positive Terminal. 7. Negative Terminal. 8. Euro fitting for MIG gun. 9. Amperage / Voltage Selector Switch. 10. Digital Meter. 11. Fine Voltage Switch. 12. Coarse Voltage Switch. 13. Warning indicator. 14. AC Power indicator. 15. Ground Screw. 16. Input Power Cable. 17. Fuse. 18. Fuse (Optional). 19.
20. Input Gas Fitting. 21. Burnback (Inside).
3.02 BOSS MIG Control Methods Weld Control MIG/MAG Description Yes 2T mode MIG Yes 4T mode MIG Yes Spot mode MIG 2T Mode 4T Mode Spot mode Table 7 3.03 BOSS MIG Series selection of weld technology in different weld methods Weld parameter description Figure 4 BOSS MIG series front panel with parameter description Parameter Welding Current Spot Time Burnback Time Description This parameter sets the welding current. MIG only.
4.0 SET-UP FOR MIG/MAG Conventional operating procedures apply when using the welding power source, i.e. connect work lead directly to work piece and connect MIG gun to the power source. 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.
5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. BOSS MIG series front panel Main Power Switch. Wire Speed Control. Spot Time Control (a spot welding nozzle required). Mode Selector Switch 4T/Spot /2T. Fine Voltage Control. Amperage / Voltage Selector Switch. Voltage Indicator. Amperage Indicator. Digital Meter. Coarse Voltage Switch. Warning Indicator. AC Power indicator.
5.01 Basic MIG Welding Guide The welding power supply has two control settings that have to balance. These are the wire speed control and the voltage control switches. The welding current is determined by the wire speed control, the current will increase with increased wire speed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current, because the wire speed is not changed.
l l l l l Capacity of the wire feed unit and power supply. The amount of penetration required. The deposition rate required. The bead profile desired The position of welding and cost of the electrode wire. Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross sectional area of electrode wire and is normally expressed as amps per mm2. An example is tabled below.
6.0 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.
Troubleshooting Guide Fault Cause Remedy 1. The AC power indicator light is not lit and welding arc can not be established. 1. No power input or main power switches damage. 2. Indicator damage. 1. Check input power or replace main power switch. 2. Replace indicator light. 2. The AC power indicator light on and welding arc can not be established. 1. Input voltage unstable. 2. Diode damage. 1. Connect stabilizer or reset power switch. 2. Replace diode. 3. The warning indicator light on. Over load.
7.02 Solving Problems Beyond the Welding Terminals The general approach to fix gas metal arc welding (GMAW) problems is to start at the wire spool then work through to the MIG gun. There are two main areas where problems occur with GMAW: a) Porosity When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal.
l l l l l Use “U”groove drive feeder roller matched to the aluminum wire size you are welding. Use “V’ ”groove drive feeder roller matched to the steel wire size you are welding. Use “knurled V”’groove drive feeder roller matched to the flux cored wire size you are welding. Mis-alignment of inlet/ outlet guides Wire will rub against the mis-aligned guides and reduces wire feed ability.
7.03 Weld Problems Fault 1. Undercut 2. Lack of penetration 3. Lack of fusion Cause Remedy A Welding arc voltage too high. B C Incorrect gun angle. Excessive heat input. A Welding current too low. B Joint preparation too narrow or gap too tight. C Shielding gas incorrect. Voltage too low. A Voltage too high. 4. Excessive spatter B Voltage too low. A Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high. 5. Irregular weld shape B Wire is wandering.
7.04 Power Supply Problems Fault 1. 2. 3. 4. 5. 6. 7. 8. Input power supply voltage is ON. Indicator light is not lit and welding arc can not be established. Input power indicator light is not lit and welding arc can not be established. Input power supply is ON and indicator light is lit but when the gun trigger switch is depressed nothing happens. Input power supply voltage is ON, no wire feed but gas flows from the MIG gun when the gun trigger switch is depressed.
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- 26 BOSS MIG 185、202、255、275 Operating Manual
Figure 9 QTY. Sequence Order No Name 1 3EER32002 TRANSFORMER,POWER ASSY,221 1 3EER32003 TRANSFORMER,POWER ASSY,251 1 3EER32013 TRANSFORMER,POWER ASSY,250 2 3EER23001 INDUCTOTR ASSY, 3 3KITP003301001 RECTIFIER,OUTPUT 3PH 250 3 3KITP003301003 RECTIFIER,OUTPUT 1PH 221 3 3KITP003301004 RECTIFIER,OUTPUT 1PH 251 4 3KITP002610020 BOARD,PCB,REALY 5 3KITP000112001 6 MIG 185 MIG 202 1 1 MIG 275 1 1 1 (7.828.
13 2LAW8805002 LABEL WARNING 1 1 1 1 14 2LAW8805004 LABEL WARNING 1 1 1 1 15 2LAC8807053 LABEL BURNBACK 1 1 1 1 16 2LAV8817013 LABEL WIRE DRIVE 1 1 1 1 17 2LAR8806016 LABEL REAR 1 1 1 1 18 2FPB6123047 BASE FP6.123.047 1 1 1 1 PANEL REAR FP8.610.108 1 1 1 1 BASE CYLINDER FP8.604.042 1 1 1 1 BRACKET CYLINDER FP6.615.001 1 1 1 1 1 1 1 1 1 1 19 20 2FPBM8604042 21 22 2FPZ8319001 AXLE 23 2FPBS8634006 BRACKET,MOUNTING FP8.634.
0.04 0.04 0.04 0.04 0.7 0.7 0.7 0.7 BUSHING,STRAIN RELIEF M24 1 1 1 1 7GS50CC001M CABLE CONNECTOR MALE 50 1 1 1 1 4TER50D12 CABLE LUG 50-12 1 1 1 1 48 8HPVC5X8BK001 GAS HOSE 5*8 0.7 0.7 0.7 0.7 49 2FPPF6176000 PANEL,FRONT (6.176.000) 1 1 1 1 50 3KITP002706011 BOARD,PCB,DISPLAY-A (7.824.
74 2FPBM8604036 BRACKET FAN MOUNTING UPPER (Inside) 1 75 2FPBM8604037 BRACKET FAN MOUNTING LOWER (Inside) 1 76 4CC010203 TERMINAL 2*3 1 1 1 1 77 4WRKSSBS26 BUSHING SNAP BS26 4 4 4 4 78 4WRNB1216 BUSHING SNAP (Inside) 1 1 1 1 79 4CDJ63V22000 CAPACITOR 63V22000uF 4 4 4 4 80 3BB7725057 BUS BAR 2 2 2 2 81 2FPPT8048047Y PANEL TOP 1 1 1 1 82 2FPPT6170006Y PANEL LEFT SIDE UPPER 1 1 1 1 83 2FPPT8048034Y PANEL LEFT SIDE LOWER 1 1 1 1 84 2LAW8805000 LA
