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Summary of Contents for Boss Mig 250
- Page 1 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. B0808...
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Page 3: Table Of Contents
2.02 Installation of MIG/MAG--------------------------------------------------------------------------------9 2.03 Specifications---------------------------------------------------------------------------------------------9 2.04 Duty Cycle------------------------------------------------------------------------------------------------10 OPERATOR CONTROLS-------------------------------------------------------------------------------11 3.01 Inverter Mig 250 Controls-----------------------------------------------------------------------------11 3.02 Inverter Mig 250 Control Methods------------------------------------------------------------------13 3.03 Weld Parameter Description-------------------------------------------------------------------------13 SET-UP FOR MIG/MAG---------------------------------------------------------------------------------14 POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------15 5.01 Basic MIG Welding Guide----------------------------------------------------------------------------16 5.02 Position of MIG GUN-----------------------------------------------------------------------------------16... -
Page 4: Symbol Legend
2T (GTAW) Gas Pre-Flow Time Voltage Reduction 4T (GTAW) Device Circuit — Repeat Function (GTAW) Negative Spot Function (GTAW) Positive High Frequency Starting Gas Input (GTAW) Lift Start £¨ GTAW£© Gas Output - 2 - BOSS Inverter Mig 250 Operating Manual... -
Page 5: Statement Of Warranty
BOSS ‘ s sole option, of any components or parts of the product determined by BOSS to be defective. -
Page 6: General Information
Do not use the welding torch in an area where combustible or explosive gases or materials are located. Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. - 4 - BOSS Inverter Mig 250 Operating Manual... - Page 7 Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. - 5 - BOSS Inverter Mig 250 Operating Manual...
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Page 8: Transporting Methods
Lift unit with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure unit on a proper skid before transporting. - 6 - BOSS Inverter Mig 250 Operating Manual... -
Page 9: Installation Recommendation
40 degrees C. WARNING 1 BOSS advises that this equipment be electrically connected by a qualified electrician. The following Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this Power Supply:... -
Page 10: Electrical Input Connections
Notice: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code). Figure 1 Electrical input connections - 8 - BOSS Inverter Mig 250 Operating Manual... -
Page 11: Installation Of Mig/Mag
220/240V 50/60Hz 1ph KVA @ max output 10KVA Max current 250A Output current range 30~250A Open circuit voltage 62/68V Duty cycle at 40¡æ Weight 40Kg Dimensions 580 350 410 Table 3 - 9 - BOSS Inverter Mig 250 Operating Manual... -
Page 12: Duty Cycle
Due to variations that can occur in manufacture products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service. - 10 - BOSS Inverter Mig 250 Operating Manual... -
Page 13: Operator Controls
Thermal overload 16. AC Power Indicator— Lights when in the ON position. 17. Ground. 18. Input Power Cable Port. 19. 110VAC Auxiliary Power. 20. Fuse. 21. Input Gas Fitting. 22. Burnback (Inside). - 11 - BOSS Inverter Mig 250 Operating Manual... - Page 14 Spool gun motor WF2 motor Spool gun motor Table 4 WARNING When the welder is connected to the primary supply voltage, the internal electrical components maybe at primary potential with respect to earth. - 12 - BOSS Inverter Mig 250 Operating Manual...
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Page 15: Inverter Mig 250 Control Methods
2T Mode 4T mode MIG 4T Mode Spot mode MIG Spot mode Table 5 Inverter Mig 250 selection of weld technology in different weld methods 3.03 Weld parameter description Figure 4 Inverter Mig 250 front panel with parame ter description Parameter... -
Page 16: Set-Up For Mig/Mag
The operator should use the welding current range values as a guide, and then finally adjust the current setting to suit the application. Figure 5 Set up for Inverter Mig 250 WARNING: Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off. -
Page 17: Power Supply Controls Indicators And Reatures
POWER SUPPLY CONTROLS INDICATORS AND REATURES Figure 6 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. -
Page 18: Basic Mig Welding Guide
Speed at which a weld travels influences the width of the weld and penetration of the welding run. 5.05 Electrode Wire Size Selection The choice of electrode wire size in conjunction with shielding gas used depends on: - 16 - BOSS Inverter Mig 250 Operating Manual... -
Page 19: Spot Welding Operation
5.06 Spot Welding Operation Fit a spot welding nozzle to the MIG gun for consistent spot welding operations. The Inverter Mig 250 power supply will operate effectively using 0.8~1.2mm electrode wire when spot welding. Penetration depth is limited when using 0.6mm electrode wire for spot welding. Set the controls as follows for spot welding: 1£®... -
Page 20: Maintenance
WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an accredited BOSS service agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the welding power source must be returned to an accredited BOSS service agent for repair. - Page 21 2. Repair or replace. rated input voltage. 9. The current decrease in the Faulty cable connected to work Make sure the cable positive connect weld process. piece. to the work piece correctly. Table 8 - 19 - BOSS Inverter Mig 250 Operating Manual...
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Page 22: Solving Problems Beyond The Welding Terminals
Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip. Wire spool brake is too loose Wire spool can unwind and tangle. Worn or incorrect feed roller size - 20 - BOSS Inverter Mig 250 Operating Manual... - Page 23 If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc. Bent liner This will cause friction between the wire and the liner thus reducing wire feed ability. - 21 - BOSS Inverter Mig 250 Operating Manual...
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Page 24: Weld Problems
E Cooling rate too fast. E Slow the cooling rate by preheating part to be weld or cool slowly. A Faulty rectifier unit. A Have an accredited BOSS service agent B Loose welding cable to test then replace the faulty component. -
Page 25: Power Supply Problems
A Replace or repair. B Gas passage contains B Disconnect gas hose from the rear impurities. of Inverter Mig 250 or then raise gas No gas flow. pressure blow impurities. C Gas regulator turned off. C Turn on the gas regulator. -
Page 26: 8.0 Parts List
8.0 PARTS LIST - 24 - BOSS Inverter Mig 250 Operating Manual... - Page 27 Figure 9 - 25 - BOSS Inverter Mig 250 Operating Manual...
- Page 28 3KITP002701030 BOARD,PCB,FILTER (7.820.006C-02) 4SNOCS300B SENSOR 300B 3KITP002706015 BOARD,PCB,DISPLAY-B (7.824.002B-02) 3KITP002303000 BOARD,PCB,CONTROL-WIRE DRIVE (7.820.506A-02) 3KITP002205030 BOARD,PCB,RELAY (7.828.011-01) 2BAR65002 SUPPORT SPOOL 3BB7725129 BUS BAR 3EER22007 ASSY,OUTPUT INDUCTOR 2LAF8802204 OVERLAY CONTROL INVERTER MIG250 BOSS - 26 - BOSS Inverter Mig 250 Operating Manual...
- Page 29 4FANCSA1725 FAN COVER 4WRKSSBS26 BUSHING SNAP BS26 2FP7854018 INSULATOR WIRE DRIVE 4JFT35X50 MOUNT NPRN 4FAN001SA1725 2PST8634004 INSULATOR FAN 481CC3KV103 CAPACITOR 3KV103 (Inside) 4WP143102A RECEPTACLE 14 PIN 4RX27D50W500H RESISTOR 50W 500 OHM - 27 - BOSS Inverter Mig 250 Operating Manual...
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Page 30: Remark
When long -time does not use, every two months should electrify a time, a humidity month of every two week should electrify use a time, by use own thermal row of tide. - 28 - BOSS Inverter Mig 250 Operating Manual...
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