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Summary of Contents for BossWeld 200X
- Page 1 INVERTER TIG/MMA WELDER MANUAL Inverter Multiprocess Welde...
- Page 2 The BOSSWELD AC/DC 200X is the latest in IGBT inverter welder technology, this precise power source delivers a smooth output in AC and DC Lift TIG, HF TIG, MMA/Stick settings, providing the user adjustments via the full digital control.
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Page 3: Table Of Contents
CONTENTS PAGE WARRANTY BOX CONTENTS WARNINGS MACHINE CARE / SAFETY INSTRUCTIONS WORK AREA SAFETY MAINTENANCE & DISPOSAL / GAS BOTTLE FRONT & REAR PANEL LAYOUT MACHINE CONTROLS PANEL 11-12 DUTY CYCLE GENERAL AC/DC WELDING GENERAL PULSE WELDING GENERAL 2T / 4T TRIGGER CONTROL GENERAL LIFT ARC / HF START 16-17 FOOT CONTROL UPGRADE OPTIONS... -
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 AC/DC 200X Inverter TIG Welder Box Contents AC/DC 200X Inverter TIG / MMA Welder 4m 26 Series TIG Torch Electrode Holder Lead Welding Earth Lead Gas Hose Carry Strap Dual Stage Argon Regulator Torch Spares (not shown) Owners Manual (not shown) -
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 / Gas Bottle
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine. We recommend that you close the cylinder valve when the machine is not in use. BOSSWELD, authorised representatives or agents of BOSSWELD will not be liable or responsible for the loss of any gas. -
Page 10: Front & Rear Panel Layout
FRONT PANEL 1. LCD Current Meter / Display 2. Overload error indicator 3. Multi-function Control Knob 4. Positive Output Connection Socket 5. Negative Output Connection 6. Remote Controller Plug 7. Gas Output Connector 8. AC/DC Selection Switch 9. Welding Mode Selection Button 10. -
Page 11: Machine Controls Panel
CONTROL PANEL Multi-Function Control Knob 1. Press down to toggle through the menu. 2. Turn clockwise to increase the value (or anti-clockwise to decrease the value) of the selected function. CONTROL DETAILS MMA / LIFT / HF Selection Switch Illuminates when Hertz is displayed on LCD panel AC / DC Selection Switch Illuminates when Amps is displayed on... - Page 12 CONTROL DETAILS - CONTINUED The labeled figure and the corresponding table explain in detail the components of the control panel. Where an indicator is lit on the control panel, the LCD panel will show the value of that indicator. Gas Pre-Flow Time Welding Base Current Seconds 0.0 –...
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Page 13: Duty Cycle
The Overload Error Indicator light indicates • Over temperature • Duty cycle exceeded AC TIG Duty Cycle 692200 BOSSWELD 200X AC/DC Duty Cycle Amperage / Current Voltage DC Duty Cycle TIG / MMA AC MMA Duty Cycle... -
Page 14: General Ac/Dc Welding
AC / DC WELDING Alternating current (AC) is electricity that switches direction back and forth so the voltage also periodically reverses because the current changes direction. Typical AC currents are what you would expect to see from your electrical outlets in your home and often used in higher voltage devices such as household appliances. AC current changes its polarity 120 times per second with a 60-hertz current. -
Page 15: General Pulse Welding
PULSE TIG WELDING TIG welding with the pulse feature is most often done for thin metals such as aluminum and can also be used with copper and varieties of steel. Pulsing can be set up with a foot pedal or as a setting on your TIG welder, but when should you use pulsing? There are some very specific applications for pulsing with a TIG welder and then there are times when it can just come in handy to get a job done better. -
Page 16: General 2T / 4T Trigger Control
2T / 4T TRIGGER CONTROL 2T Trigger Control 1. Press the trigger and Hold 2. The set pre-gas flow starts and the arc starts and will upslope to the amperage selected on the amperage dial. 3. When you want to finish the weld, release the trigger and the amperage will begin to downslope at the rate you have selected on the downslope dial, If you selected zero the arc will stop as soon as you release the trigger. -
Page 17: Foot Control Upgrade Options
Press the button on the TIG torch FOOT CONTROL - OPTIONS Bossweld Foot Control 3mt Part No: 660201 3 metre cord Ideal for bench work Parent-Child relationship between the welder and foot controller. This means if you set the welder to 120 Amps, the foot controller range will be between min and 120 Amps. -
Page 18: Stick / Mma Welding Setup
MACHINE SET UP STICK/MMA Note: The below image shows setup for DCEP / Negative Polarity (Most Common application) 6.Select Stick / MMA mode 2. Connect Electrode holder to the terminal 3. Connect earth Clamp to the terminal Plug the machine 15Amp input power lead into the Connect earth clamp firmly to work-piece wall socket, ensuring that the power switch on ensuring that the clamp makes good contact... - Page 19 MACHINE SET UP STICK/MMA - CONTINUED Ensure the electrode/electrode holder is not Select your required amperage by near the work-piece or can earth out, turn the turning the Multi-Function Control knob machine on using the mains power switch. The front displays will light up and the cooling fan will start.
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Page 20: Electrode / Current Selection
ELECTRODE SIZE SELECTION Electrode size selection will be determined by the thickness of the section being welded. A thicker section will need a larger diameter electrode. The table below shows the maximum size of electrodes for average thicknesses of section (based on General Purpose 6013 Electrode). Average Metal Thickness Electrode Size 1.0 - 2.0mm... -
Page 21: General Mma Welding
MANUAL METAL ARC PROCESS (MMA WELDING) When an arc is struck between the metal rod (electrode) and the workpiece, both the rod and workpiece surface melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas and slag which protects the weld pool from the surrounding atmosphere. - Page 22 MACHINE SET UP TIG WELD 4. Connect the Argon Gas Regulator 2. Connect the Gas hose to the supplied to the Gas bottle and connect the Gas Output and the Gas Hose to the Gas Input socket on the TIG Torch Control Socket and rear of machine and the Regulator.
- Page 23 We recommend that you close the cylinder valve when the machine is not in use. BOSSWELD authorised representatives or agents of BOSSWELD will not be liable or responsible for the loss of any gas.
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Page 24: Ac/Dc Weld Cycle Setup
BASIC WELD CYCLE EXPLANATION Pre Gas Selection for gas flow time prior to the arc starting. Start Current Selection for the amount of amps required at the start of the weld. UpSlope Selection for the transition time from Start Amperage to Peak Amperage. Peak Current Selection for the Maximum Welding Amperage required during welding. - Page 25 AC/DC TIG WELD CYCLE SETUP Pressing the Multi-Function Control Pressing the Multi-Function Control knob knob to cycle to Peak Current then to cycle to Pre Gas then adjusting to the adjusting to the required parameter required parameter Amps TIG DC 10 - 170 0.0 - 2.0 Seconds TIG AC 10 - 200 MMA DC 10 - 200...
- Page 26 AC/DC TIG WELD CYCLE SETUP Pressing the Multi-Function Control knob to cycle to Width or duration of base Pressing the Multi-Function Control current then adjusting to the required knob to cycle to Crater Arc Current then parameter adjusting to the required parameter 5-95 Seconds DC 10- 170...
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Page 27: Tig Welding Setup
TUNGSTEN SELECTION / PREPARATION & GRINDING ELECTRODES Electrodes for DC welding are normally pure tungsten with 1 to 4% thoria to improve arc ignition. Alternative additives are lanthanum oxide and cerium oxide which are claimed to give superior performance (arc starting and lower electrode consumption). -
Page 28: Tig Welding Continued
WORK PIECE WORK PIECE TIG WELDING - CONTINUED This risk can be minimised using the ‘lift arc’ technique where the short-circuit is formed at a very low current level. The most common way of starting the TIG arc is to use HF (High Frequency). HF consists of FLUX COATING high voltage sparks of several thousand volts which last for a few microseconds. -
Page 29: Tig Torch Breakdown
BOSSWELD 26 SERIES 200AMP TIG TORCH SPARE PARTS PART NO. DESCRIPTION 95.26F.4.1.CC12A Tig Torch 26, 4mt, 1 pc, Current control, Flexi Head 95.26F.8.1.CC12A Tig Torch 26, 8mt, 1 pc, Current control, Flexi Head BACK CAP INSULATOR COLLET TORCH BODY PART NO. -
Page 30: Trouble Shooting
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 31 • Something caught in the valve • Remove • Solenoid valve is damaged, • Contact BOSSWELD hotline OPERATIONAL ENVIRONMENT • Height above sea level ≤1000m • Operation temperature range -10~+40°C • Air relative humidity is below 90%( 20°C) •...
- Page 32 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 • WELDING CABLE...
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