MODEL • Inverter Mig 250 Operating Manual (Owner’ s Manual) IMPORTANT: Read these instructions before installing, operating, or servicing this system. First Edition October, 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 Inverter Mig 250 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 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. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.
2.04 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and 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.
3.0 OPERATOR CONTROLS 3.01 Inverter Mig 250 controls Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Main Circuit Bleaker— Switching to the ON position energizes the welding power source. Selector Control— 2T/ Spot/ 4T Spot Time 14-Pin Receptacle— Used to connect the wire feeder. Wire Feed Speed Control. Voltage Control. Positive Terminal— 50mm Screw receptacle. Negative Terminal— 50mm Screw receptacle. Terminal— Use to connect the torch. Down Slope Voltage Control (Optional).
Figure 3 Pin WF2 function 4 inch spool gun function A Torch switch input Torch switch input 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 4 WARNING When the welder is connected to the primary supply voltage, the internal electrical
3.02 Inverter Mig 250 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 5 3.03 Inverter Mig 250 selection of weld technology in different weld methods Weld parameter description Figure 4 Inverter Mig 250 front panel with parame ter 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. 13. 14. 15. Inverter Mig 250 front panel Main Power Switch. Mode Selector Switch 2T/ Spot/ 4T Spot Time Control (a spot welding nozzle required). 14-Pin Receptacle— Used to connect the wire feeder. Wire Feed Speed Control. Voltage Control. Down Slope Amperage Control (Optional). Down Slope Voltage Control (Optional). Meter Selection. Voltage Indicator. Speed Indicator. Amperage Indicator. Digital Meter.
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 l l Thickness of the metal to be welded. Type of joint. 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 PCB damage. 1. Connect stabilizer or reset power switch. 2. Repair or replace. 3. The warning indicator light on.
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. 9. 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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Figure 9 - 25 BOSS Inverter Mig 250 Operating Manual
Sequence Order No Name 1 3KITP000505052 BOARD,PCB,CONTROL 2 3KITP000206019 OUTPUT 250L 2-1 3KITP000506016 BOARD,PCB,MOSFET (7.820.
16 2LAC8807079 LABEL POWER L 1 17 2LAU8803009 LABEL (+) 1 18 2LAU8803010 LABEL (-) 1 19 2LAN8808352 LABEL MANUFACTURERS RATING Inverter MIG250 BOSS 1 20 2LAM8800003 LABEL GROUND 1 21 2LAU8801001 LABEL GAS INPUT 1 22 2LAM8800001 LABEL VOLTAGE INPUT 240V 1PH 1 23 2LAM8806009 LABEL FUSE 1 24 2LAM8806020 LABEL AUXILIARY POWER 115V 1PH 1 25 2LAW8805002 LABEL WARNING 1 26 2LAW8805004 LABEL WARNING 1 27 2LAC8807053 LABEL BURNBACK 1 28 2LAV8817013 LABEL MOTOR 1 29
57 4RX27D20W0R47H RESISTOR 20W 0.
