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Table of Contents
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Summary of Contents for BossWeld M100
- Page 1 M100 INVERTER GASLESS MIG WELDER MANUAL YEAR LIMITED WARRANTY...
- Page 2 The BOSSWELD M100 is the latest in IGBT Inverter welder technology, this very portable MIG welder is easy to set up, easy to use, enabling the user to complete smooth welds with Gasless MIG wire. Ideal for around the home, DIY workshop, or rural applications.
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Page 3: Table Of Contents
CONTENTS PAGE WARRANTY BOX CONTENTS WARNINGS MACHINE CARE / SAFETY INSTRUCTIONS WORK AREA SAFETY MAINTENANCE & DISPOSAL FRONT & REAR PANEL LAYOUT MACHINE INSIDE MACHINE SET UP 12-13 DUTY CYCLE / DRIVE ROLLER SIZE MIG TORCH AND CONSUMABLE CARE BASIC MIG WELDING GUIDE 16-17 COMMON WEAR PART BZ15 MIG TORCH PARTS BREAK DOWN... -
Page 4: Warranty
7. Use on Incorrect voltage or non authorised electrical connections and plugs 8. Use of non standard parts 9. Repair, case opening, tampering with, modifications to any part of the item by non authorised BOSSWELD repairers. This warranty covers the machine only and does not include Torches, Leads, Earth Clamps, Electrode holders, Plasma Torches, TIG Torches and any of the parts on those items unless there is a manufacturing fault. -
Page 5: Box Contents
BOSSWELD M100 Inverter Gasless MIG Welder Box Contents BOSSWELD M100 Inverter Gasless MIG Welder Direct Connect MIG Torch 2.5M Direct Connect welding Earth cable with Earth Clamp Carry Strap Cable / Lead tidy Torch Spares Gasless 0.6-0.8mm Driver Roller (Installed) -
Page 6: Warnings
WARNING The device and packaging material are not toys! Children must not be allowed to play with the machine and its accessories. Plastic parts and packaging are choking risks for children. • Open the packaging and remove the welder carefully. •... -
Page 7: Machine Care / Safety Instructions
MACHINE CARE / SAFETY Keep the welding cables, earth clamp and electrode holder in good condition. Failure to do this can result in poor welding quality, which could be dangerous in structural situations. Prior to use, check for breakage of parts and any other conditions that may affect operation of the welder. Any part of the welder that is damaged should be carefully checked to determine whether it will perform its intended function whilst being safe for the operator. -
Page 8: Work Area Safety
WORK AREA Ensure a clear, well lit work area with unrestricted movement for the operator. The work area should be well ventilated, as welding emits fumes which can be dangerous. Always maintain easy access to the ON/OFF switch of the welder, and the electrical mains supply. Do not expose the welder to rain and do not operate in damp or wet locations Where welding must be undertaken in environments with increased risk of electric shock, confined spaces or in the presence of flammable or explosive materials, it is important that the environment be evaluated in advance... -
Page 9: Maintenance & Disposal
MAINTENANCE WARNING Before starting any cleaning, or maintenance procedures on the welding machine, make sure that it is switched OFF and disconnected from the mains supply. There are no user serviceable parts inside the welder. Refer to a qualified service personnel if any internal maintenance is required. -
Page 10: Front & Rear Panel Layout
FRONT PANEL 1. Power Light Indicator 2. Overload Error Indicator Light 3. Welding Voltage Control Knob 4. Wire Speed Control Knob 5. Welding Earth Lead 6. MIG Torch Output REAR PANEL 7. Cooling Fan 8. Mains Power Switch 9. 240V AC Mains Power Cord 10. -
Page 11: Machine Inside
SIDE PANEL (DOOR OPEN) A. Spool Hub NOTE: This unit is suitable for D100 Rolls of Gasless MIG Wire (<1Kg in weight) B. Spool Hub Nut C. Wire Drive Assembly D. Drive Roller E. Drive Roller Cover F. Idle Roller G. -
Page 12: Machine Set Up
MACHINE SET UP GASLESS MIG WELDING Remove the Drive Roller Cover. Check Open the side door of the machine. the Drive roller is matched to the wire size for the job Note: Correct wire side on roller to face out off machine when Then replace the Drive Roller fitting. - Page 13 Connect earth clamp to the work Re install tip over the wire and tighten, piece ensuring that the clamp Do NOT over tighten, or you may damage makes good contact with bare metal. the tip holder and re-attach nozzle to torch.
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Page 14: Duty Cycle / Drive Roller Size
DUTY CYCLE: Special note: If this welders duty cycle is exceeded the welder will enter “thermal overload” which will automatically stop the welding output in order to protect, both the user and the welder. You will know the welder has gone into thermal overload when the thermal overload light is illuminated. The welder will then cool itself down, and once the thermal overload indicator light is no longer illuminated, welding can then re-commence. -
Page 15: Mig Torch And Consumable Care
MIG torch parts. This silicon free compound is used to prolong the life of nozzles & tips. Bossweld 8 Ways MIG Welding Pliers (Part No: 800074) Handy 8 function welders pliers. Functions include, nozzle removal, tip removal, cleaning inside of nozzle... -
Page 16: Basic Mig Welding Guide
BASIC MIG WELDING GUIDE The welding power supply has two control settings that have to balance. These are voltage control switches and the wire speed control. The welding amperage is determined by the voltage settings, the wire diameter, gas selection and the wire feed speed. The amperage will increase with higher voltage selection on the machine and higher wire feed speed. - Page 17 GMAW (MIG) WELDING Metal inert gas (MIG) welding is an attractive alternative to MMA (stick welding), offering high deposition rates and high productivity. PROCESS CHARACTERISTICS MIG welding is a versatile technique suitable for both thin sheet and thick section components. An arc is struck between the end of a wire electrode and the workpiece, melting both of them to form a weld pool.
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Page 18: Common Wear Part
Recommend using Gasless 0.8mm x 0.9kg BZ15 BOSSWELD BINZEL STYLE DIRECT CONNECT MIG TORCH Please note: This replacement torch must be replaced by Bossweld or an authorised service centre Failure to do so will void your machine warranty. PART NO. -
Page 19: Welding Consumables
Wooden handled wire brushes used for cleaning & preparation of metals pre & post welding. . CODE DESCRIPTION 700010 Bossweld 16”” Black & Gold Welding Glove Bossweld 16inch Welding Gloves Bossweld 16 inch welding gloves available in black and Gold cow split leather. VISIT BOSSWELD.COM.AU FOR A FULL RANGE OF WELDING CONSUMABLES... -
Page 20: Helpful Information & Trouble Shooting
• After cooling, the protector will reconnect the supply circuit and the welder will be ready for further use. Note: If the duty cycle of the machine is exceeded, the thermostatic protection will activate and the machine will cut out, to cool down. For Further Tips and Information please visit Bossweld TV Scan here to visit Bossweld TV... - Page 21 TROUBLE SHOOTING Issue Possible Reason Suggested Remedy Power indicator is not lit, • Welder is not plugged into • Check that the welder is plugged into the fan does not work and no power supply 240V mains outlet and is switched on. output current •...
- Page 22 TROUBLE SHOOTING - CONTINUED Issue Possible Reason Suggested Remedy Porosity - small cavities or • Gas nozzle clogged with • Clean or replace the gas nozzle holes resulting from gas spatter, worn or out of shape pockets in weld metal •...
- Page 23 MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MIG welding. Issue Possible Reason Adjusting wrong dial • Be sure to adjust the wire feed and voltage dials for MIG welding. Incorrect wire speed setting •...
- Page 24 Version 1.0 2019 OTHER PRODUCTS IN OUR RANGE • ELECTRODES • MIG WIRE • TIG RODS • GAS EQUIPMENT • WELDING HELMETS • WELDING SAFETY • WELDING MACHINES • MIG TORCHES • TORCH SPARE PARTS • TIG TORCHES • WELDING ACCESSORIES •...
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