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BossWeld MST 250XT Manual

Multiprocess dc inverter manual
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CONDITIONS
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CONDITIONS
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CONDITIONS
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CONDITIONS
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DC INVERTER MANUAL
MULTIPROCESS
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Summary of Contents for BossWeld MST 250XT

  • Page 1 CONDITIONS CONDITIONS APPLY APPLY MULTIPROCESS CONDITIONS CONDITIONS APPLY APPLY DC INVERTER MANUAL...
  • Page 2 The BOSSWELD MST 250/350XT is the latest in IGBT multipurpose welder technology, this very portable power source enables the user to complete high quality welds in both MIG - TIG - MMA/Stick electrode applications.

  • Page 3: Table Of Contents

    CONTENTS PAGE WARRANTY BOX CONTENTS WARNINGS MACHINE CARE / SAFETY INSTRUCTIONS WORK AREA SAFETY MAINTENANCE & DISPOSAL / GAS BOTTLE MACHINE SPECIFICATIONS 10-11 FRONT & REAR PANEL LAYOUT MACHINE CONTROLS PANEL MACHINE INSIDE / DUTY CYCLE 14-15 WIRE SPOOL & WIRE FEED SET UP MIG TORCH SETUP LINER INSTALLATION / REPLACEMENT DRIVE ROLLER SIZE...

  • 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 MST 250/350XT Multi-Process Inverter Welder Box Contents BOSSWELD MST 250/350XT Inverter DC MIG Welder 4 metre 24 Series MIG Torch (250XT only) 4 metre 36 Series MIG Torch (350XT only) 3 metre twist lock electrode holder 3 metre Earth cable with earth clamp...

  • 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 The Bossweld MST 250XT is a multi-process, inverter-based welder that provides the opportunity to MIG, Stick and TIG weld from the same machine. Heavy duty and designed for industrial use; the 250 Amps at 60% delivers ample power, and the front swivel wheels make it easy to manoeuvre.
  • Page 11 The Bossweld MST 350XT is a multi-process, inverter-based welder that provides the possibility to MIG, Stick and TIG weld from the same machine. Heavy duty and designed for industrial use, the 285 Amps at 60% provides ample power, and the front swivel wheels make it easy to manoeuvre.

  • Page 12: Front Panel

    FRONT PANEL 1. Control Panel 2. MIG Torch Connection Socket 3. Positive Output Connection Socket 4. Polarity Cable 5. Gas Output Connection 6. Remote Controller Plug 7. Negative Output Connection Socket REAR PANEL 8. Gas Cylinder Securing Chain 9. Mains Power Cord 10.

  • Page 13: Control Panel

    CONTROL PANEL Welding Method Overload Error Indicator Press to select MIG / Stick MMA / TIG Lift Arc Illuminates when the machine is overloaded Current / wire feed speed Display Downslope • • Displays the Welding current in Amps. Adjust the downslope current - TIG Only (when 6 is lit) MMA Main Power ON/OFF •...
  • Page 14 SIDE PANEL (DOOR OPEN) A. Spool Hub B. Spool Hub Nut C. Wire Feed Tensioning Adjustment D. Idle Rollers / Wire Tensioning Arms E. Drive Roller Retainer Nut F. Wire Guide Inlet Tube G. Wire Inlet H. Burnback, Slow Feed, Post Flow, Pre-Flow Adjustment Panel Storage Compartment SETTING MACHINE POLARITY...

  • Page 15: Machine Inside / Duty Cycle

    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 overload error indicator light is illuminated. The welder will then cool itself down, and once the overload error indicator light is no longer illuminated, welding can then re-commence.
  • Page 16 SET UP OF WIRE SPOOL & WIRE FEED UNIT Remove the Drive Roller Covers. Check Open the side door of the machine. the Drive rollers are matched to the wire size for the job Note: Correct wire side on roller to face into machine when fitting.
  • Page 17 SET UP OF MIG TORCH Attach the Euro Connect MIG Press the trigger. This will feed torch to the machine feeding the the wire through the torch. wire into the liner. Release button when wire appears at the end of the torch. Tighten MIG Torch connector to machine.

  • Page 18: Liner Installation / Replacement

    MIG TORCH LINER INSTALLATION / REPLACEMENT Re install tip and tighten Carefully feed the new Lay the MIG torch out using the tool provided liner into the torch lead all straight and flat on the and re attach nozzle to the way out the end of the ground and remove the torch.

  • Page 19: Trigger Control

    MACHINE DRIVE ROLLER SIZE (NOTE: MACHINE WILL RUN UP TO 1.2MM WIRE) PART No: DESCRIPTION Knurled Drive Roller For Gasless Wire RK302210.08.10 Drive Roller 0.8/1.0mm Knurled 30 x 22 x 10mm 10mm RK302210.09.12 Drive Roller 0.9/1.2mm Knurled 30 x 22 x 10mm RK302210.10.12 Drive Roller 1.0/1.2mm Knurled 30 x 22 x 10mm 30mm...

  • Page 20: Final Thoughts

    MIG torch parts. This silicon free compound is used to prolong the life of nozzles & tips. Bossweld 8 Ways MIG Welding Pliers Handy 8 function welders pliers. Functions include, nozzle removal, tip removal, cleaning inside of nozzle...
  • Page 21 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/3 Phase input power Connect earth clamp firmly to work-piece lead into the wall socket, ensuring that the ensuring that the clamp makes good contact...
  • Page 22 MACHINE SET UP STICK/MMA - CONTINUED Ensure the electrode/electrode holder is not You can adjust the Arc force by using voltage near the work-piece or can earth out, turn the Parameter adjustment knob. machine on using the mains power switch. The front displays will light up and the cooling fan will start.
  • Page 23 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 24: Drive Roller Size

    MACHINE SET UP GASLESS MIG WELDING 8.Select MIG mode 4. Connect MIG Torch to the Euro Connection terminal NOTE: Ensure connector nut is tighten firmly 6. Connect earth Clamp to the terminal Plug the machine 15Amp/3 Phase input power Set up the wire feed unit as per section “Set lead into the wall socket, e nsuring that the up Wire Feed Unit”.
  • Page 25 MACHINE SET UP GASLESS MIG WELDING CONTINUED Ensure the polarity is correct for gasless Press the Welding Mode Selection Button to welding, DCEN select MIG. SETTING MACHINE POLARITY DCEN - GASLESS DCEP - GAS Remove nozzle and tip from torch and press trigger on the welding torch, this will feed the wire through the torch.
  • Page 26 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 27 MACHINE SET UP GAS MIG WELDING CONTINUED Plug the machine 15Amp/3 Phase input power Install Euro connect MIG torch over the lead into the wall socket, ensuring that the protruding wire, line up the spring connectors power switch on the machine is in the OFF and screw the Euro connector nut up firmly.
  • Page 28 MACHINE SET UP GAS MIG WELDING CONTINUED Re install tip and nozzle to torch and trim wire Switch the machine on using the mains power to the end of the nozzle. The multifunction switch. Wait a few seconds whilst the machine digital display will show two numbers.
  • Page 29 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. Note: Pictures may vary from your machine model...
  • Page 30 NOTE: SPOOL GUN IS NOT SUPPLIED WITH MACHINE - SEE PAGE 43 FOR TORCH OPTIONS MACHINE SET UP SPOOL GUN WELDING 11.Select MIG mode 2. Connect Spool Gun to the Euro Connection terminal NOTE: Ensure connector nut 17 & 18. Fit gas regulator to is tighten firmly bottle and install gas hose to the inlet on the back panel of...
  • Page 31 MACHINE SET UP SPOOL GUN WELDING CONTINUED Replace the spool cover and close the wire Release the wire tensioning arm, and check drive cover the correct drive roller size matches the wire being used Turn the spool gun switch on the machine Feed the wire over the drive roller and into the control panel to ON inlet guide, make sure you hold the spool to...
  • Page 32 MACHINE SET UP SPOOL GUN WELDING CONTINUED Press the Welding Mode Selection Button to Connect earth clamp to the work piece select MIG. ensuring that the clamp makes good contact with bare metal. Remove nozzle and tip from torch and press It is recommended for ease of use that the trigger on the torch, this will feed the wire wire-feed target speed is adjusted first and...
  • Page 33 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. Note: Pictures may vary from your machine model...

  • Page 34: 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 35: Carbon Steel

    Welding Wire Selection Guide WELDING WIRE SELECTION GUIDE Carbon Steel Mig Wire, Gas Shielded Gasless, Flux Core Wire 0.6mm 0.8mm 0.9mm 1.2mm 0.8mm 0.9mm 1.2mm 30-45 45-60 50-60 60-75 70-80 50-65 70-105 90-110 90-110 70-90 75-90 120-130 120-130 90-105 95-120 135-150 135-150 110-135...

  • Page 36: Process Characteristics

    MIG WELDING SETTING GUIDES Welding current Welding Volt Wave control Wire Speed (Wire Size) 0.6mm 0.8mm 1.0mm 13~15V 2--3 14~16V 3--5 2--3 15~17V 6--8 3--5 2--3 100A 16~19V 8--10 3--6 120A 17~20V 4--7 3--5 140A 19~21V 5-10 5--8 3--5 160A 20~22V 5-10 6--9...

  • Page 37: Work Piece

    GMAW (MIG) WELDING CONTINUED SHIELDING GAS In addition to general shielding of the arc and the weld pool, the shielding gas performs a number of important functions: • Forms the arc plasma • Stabilizes the arc roots on the material surface •...
  • Page 38 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 39 MACHINE SET UP DC TIG WELD - CONTINUED Fit the Earth lead Dinse Plug to the positive To adjust the Welding Current rotate the knob terminal for gasless welding and then connect to the desired Amperage. earth clamp to the work piece ensuring that the clamp makes good contact with bare metal.
  • Page 40 OPTIONAL REMOTE CURRENT & FOOT CONTROL REMOTE CURRENT SET UP Note: Current Control TIG Note: Foot Controller Torch sold separately. sold separately. Visit Visit www.bossweld.com. www.bossweld.com.au au for more information for more information Set up TIG torch as per “MACHINE SET UP Set up TIG torch as per “MACHINE SET UP...

  • Page 41: Tungsten Preparation

    WORK PIECE WORK PIECE WORK PIECE WORK PIECE TUNGSTEN PREPARATION & GRINDING Grinding creates the greatest hazard as the exposed tungsten/thoria area is greatly increased and fine particles of potentially radioactive dust are released into the atmosphere. It is recommended that a dedicated grindstone with local dust extraction is used, and a simple filter mask is worn.
  • Page 42 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 43 92.ER.24.3 BZ Style 24 MIG Torch 3m 92.ER.24.4 BZ Style 24 MIG Torch 4m 92.ER.24.5 BZ Style 24 MIG Torch 5m BOSSWELD BINZEL STYLE 24 MIG TORCH SPARE PARTS M6 Standard Duty M6 Heavy Duty M6 Aluminium PART NO. DESCRIPTION ORIGINAL REF PART NO.
  • Page 44 BZ36 BOSSWELD BINZEL STYLE MIG TORCH SPARE PARTS M6 Standard Duty M6 Heavy Duty M8 Contact Tip PART NO. DESCRIPTION ORIGINAL REF PART NO. DESCRIPTION ORIGINAL REF 92.02.36.12 Adjustable tapered nozzle ø 12mm 145.0126 92.01.25.06 Contact tip heavy duty 0.6mm x M6 x 140.0005...
  • Page 45 BOSSWELD 26 SERIES 180AMP TIG TORCH COMPLETE & SPARES BACK CAP INSULATOR PART NO. DESCRIPTION 95.26F.4.1.SW9A Bossweld 26 Series TIG Torch 4mt 9 pin Plug COLLET TORCH BODY 95.26F.8.1.SW9A Bossweld 26 Series TIG Torch 8mt 9 pin Plug COLLET BODY GAS LENS COLLET BODY PART NO.
  • Page 46 BOSSWELD 4 METRE SPOOL GUN 180AMP - 9PIN BOSSWELD 3 METRE SPOOL GUN 240AMP - 9 PIN Suits the X Series range of MIG BOSSWELD BINZEL STYLE 15 MIG TORCH welders PART NO. DESCRIPTION 92.ER.15.3 BZ Style 15 MIG Torch 3m 92.ER.15.4...

  • Page 47: Helpful Information

    HELPFUL INFORMATION Filler Metal Notes Solid Mild Steel wire • Use Industry standard - copper coated ER70S-6 Steel MIG Wire. This requires a shielding gas (CO2 or argon/CO2 mix),excellent results on panel steel. Gasless Flux cored Mild • Use Industry standard flux cored ER71T-GS Steel MIG Wire. Steel Wire This does not require a shielding gas.

  • Page 48: Troubleshooting

    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 49 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 50: Operational Environment

    MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MIG welding. Issue Possible Reason Suggested Remedy No wire feed • Wrong mode selected • Check that the TIG/MMA/MIG selector switch set to MIG position Inconsistent / interrupted •...
  • Page 52 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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