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BossWeld MST X250 PFC User Manual

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  • Page 1 USER MANUAL...

  • Page 2: Statement Of Warranty

    STATEMENT OF WARRANTY LIMITED WARRANTY: “Dynaweld” warrants to customers of its authorised distributors hereafter “Dynaweld” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Dynaweld products as stated below, Dynaweld shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Dynaweld’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or...

  • Page 3: Table Of Contents

    CONTENT CONTENT 1 Safety ..................... 1   1.1 Signal Explanation ......................1   1.2 Arc Welding Damage ..................... 1   1.3 The knowledge of Electric and Magnetic Fields ............5   2 Overview ..................7   2.1 Brief Introduction ......................7   2.2 Working Principle ......................

  • Page 4: Safety

    SAFETY Safety 1 Signal E Explana ation  T The above s signals mea an warning! Notice! R Running part ts and getti ing an elect tric shoc ck or therm mal parts wil ll take dam age for you ur body or o others.
  • Page 5 SAFETY sure to insta all the equip pment corre ctly and gro ound the wo ork or meta al to be weld to a a good electr rical (earth) ) ground acc cording the operation m manual. he electrode e and work (or ground) ) circuits ar re electrical...
  • Page 6 SAFETY degr reasing, cle eaning or sp praying ope erations. Th he heat and rays of the e arc can re eact with h solvent v vapors to f form phosg gene, a hig ghly toxic gas, and o other irritat ting prod ducts.
  • Page 7 SAFETY not spill fu uel when fi filling tank. If fuel is spilled, wip pe it up an nd do not st tart ine until fum mes have be een elimina ated. ELDING SPARKS S can caus se fire or explosion ...

  • Page 8: The Knowledge Of Electric And Magnetic Fields

    SAFETY Rotating p arts may be dange erous.  U Use only co ompressed g gas cylinde ers containin ng the corr rect shieldin ng gas for proc cess used a and properl y operating g regulators s designed for the gas s and press used d.
  • Page 9 SAFETY  Never coil the power cable around your body.  Make sure welding machine and power cable to be far away from the operator as far as possible according to the actual circumstance.  Connect the work cable to the workpiece as close as possible to the area being welded.

  • Page 10: Overview

    OVERVIEW 2 Overview 2.1 Brief Introduction MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer.

  • Page 11: Working Principle

    OVERVIEW 2.2 Working Principle The working principle of MIG SERIES arc welding machine is shown as the following figure. Single-phase 220V work frequency AC is rectified into DC （350V） , then is converted to medium frequency AC (about 40KHz) by inverter device (IGBT), after reducing voltage by medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes), and is outputted by inductance filtering.
  • Page 12 OVERVIEW （V） Volt-ampere characteristic The relation between the rated loading Working point voltage and welding current （A） 2.4Principles of welding - 9 -...

  • Page 13: Installation And Adjustment

    INSTALLATION AND ADJUSTMENT 3 Installation and Adjustment 3.1 Parameters Model MultiMIG200PFC MST X250 PFC Parameters Input Voltage（V） 1-110±10% 1-220±10% 1-110±10% 1-220±10% 31.7 Input Current（A） MMA 37 19.5 Input Power（KW） 40-140 40-200 40-160 40-250 Welding Current（A） MMA 10-110 10-200 MMA 10-130...

  • Page 14: Equipment Connection

    INSTALLATION AND ADJUSTMENT If transformer is over-heat, the heat relay inside it will open and will output an instruction to circuit board, cut AC relay and the output welding current, and brighten the over-heat pilot lamp in the front panel. At this time, the machine should be relaxed for 15 minutes to cool the fan. When operating the machine again, the welding output current or the duty cycle should be reduced.
  • Page 15 INSTALLATION AND ADJUSTMENT Operation Steps： 1、Connect the power source input cable of welding machine with the output port of air switch in electric box on the spot. 2、Connect the cable plug of wire feeder to the positive output of welding machine. 3、Connect the control cable plug of wire feeder to the aero socket on the front board of welding machine.
  • Page 16 OPERATION 3.4 Maintenance of MIG Gun mechanism 3.4.1 Dissection graphics for the MIG GUN 3.4.2 The parts list for the MIG GUN Description QTY. Remark Tip D.12 14-15AK Electric nozzle 0.8/M6*25 15AK Goose gun neck（Hexangular adapter and Plastic adapter） 15AK Goose gun Hexangular adapter Plastic adapter MIG blue handle...
  • Page 17 OPERATION 3.4.3 The operation for the MIG GUN 1. Service the wire feed mechanism at least every time the reel is changed. ·Check the wear of the feed roll groove and change the feed roll when necessary. ·Clean the welding gun wire guide with compressed air. 2.

  • Page 18: Operation

    OPERATION 4 Operation 4.1 Layout for the front and rear panel - 15 -...
  • Page 19 OPERATION 1. Choose welding mode key: On TIG or MIG, Pressing the key can choose 2T or 4T welding mode. 2. Welding current knob: Set the welding current. 3. Choose welding method key: Pressing the key can choose three function, MMA/TIG/MIG.

  • Page 20: Welding Operation

    OPERATION 18.Remote Switch 19. Manual wire switch & air check switch: up for manual wire and down for air check. 20.Burnback knob 21.Slow feed knob 22.Post flow knob 23.Pre-flow knob 4.2 Welding operation For example MULTIMIG 200 MIG mode operation: 4.2.1 1.
  • Page 21 OPERATION 3)Press the welding mode key, choose 2T or 4T； 4)Spool Gun Switch turn on(up): 3. Adjust Welding parameter 1) Different wire diameter ,the minimum welding current is different； 2) Adjust the current knob , the corresponding welding voltage is changed automatically； 3) When the programmable welding voltage isn’t the perfect for the operator, the voltage can be changed tinily by adjusted the knob；...

  • Page 22: Welding Parameters

    OPERATION MMA mode operation: 4.2.3 1. Press the weld manner key, choose MMA manner and the MMA LED is lighted； 2. Adjust the current knob to control the welding current； 3. Adjust the welding arc force knob to control the arc force current. Note：The current display is preset current before welding and is welding current when welding.

  • Page 23: Operation Environment

    OPERATION 4 .4Operation environment Height above sea level ≤1000 M ▲ ▲ Operation temperature range -10～+40℃. ▲ Air relative humidity is below 90 %( 20℃). ▲ Preferable site the machine some angles above the floor level, the maximum angle does not exceed 15℃.

  • Page 24: Maintenance & Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING 5 Maintenance & Troubleshooting 5.1 Maintenance In order to guarantee that arc welding machine works high-efficiently and in safety, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machine more , enable customers to carry on simple examination and safeguarding by oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service life of arc welding machine .Maintenance items in detail are in the following table.

  • Page 25: Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING Using the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, the fast recover diode and PCB, etc. Monthly Check up the bolt in arc welding machine, if it is loose, please screw down it. examination If it is skid, please replace.
  • Page 26 MAINTENANCE AND TROUBLESHOOTING If there are some simple troubles of MIG SERIES welding machine, you can consult the following Chart: Troubles Reasons Solution Breaker damaged Change it Close the breaker, but the Fuse damaged Change it power light isn’t on Power damaged Change it After welding machine is...

  • Page 27: Electrical Schematic Drawing

    MAINTENANCE AND TROUBLESHOOTING 5.3Electrical schematic drawing - 24 -...
  • Page 28 NOTES CONTACT DETAILS Dynaweld Industrial Supplies Pty. Ltd. 5 Sheridan Close Milperra NSW 2214 Phone: (02) 9772 1144 Fax: (02) 9771 5375 www.bossweld.com.au...

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