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Summary of Contents for Boss TIG 160HF
- Page 1 MODEL BOSS TIG 160HF BOSS TIG 200HF Operating Manual (Owner’ s Manual) IMPORTANT: Read these instructions before installing, operating, or servicing this system. First Edition September, 2008 Manual No. B0807...
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Page 2: Table Of Contents
7.02 Effects of stick welding various materials---------------------------------------------------------19 MAINTENANCE--------------------------------------------------------------------------------------------20 BASIC TROUBLESHOOTING-------------------------------------------------------------------------20 9.01 Check the item and excrescent phenomenon exclusion method---------------------------20 9.02 TIG welding problems---------------------------------------------------------------------------------22 9.03 Stick welding problems--------------------------------------------------------------------------------23 9.04 Power source problems-------------------------------------------------------------------------------24 10.0 PARTS LIST-------------------------------------------------------------------------------------------------25 11.0 REMARK-----------------------------------------------------------------------------------------------------30 - 1 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 3: 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 TIG 160HF¡¢ 200HF Operating Manual... -
Page 4: Statement Of Warranty
BOSS ‘ s sole option, of any components or parts of the product determined by BOSS to be defective. -
Page 5: 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 TIG 160HF¡¢ 200HF Operating Manual... - Page 6 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 TIG 160HF¡¢ 200HF Operating Manual...
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Page 7: 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 TIG 160HF¡¢ 200HF Operating Manual... -
Page 8: 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: Minimum primary current Current &... -
Page 9: 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 TIG 160HF¡¢ 200HF Operating Manual... - Page 10 Re-radiation from Unearthed Metallic Objects A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads .Effective grounding of such objects will prevent re-radiation in most cases. - 9 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
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Page 11: Specifications
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 TIG 160HF¡¢ 200HF Operating Manual... -
Page 12: Operator Controls
TIG HF Series Controls Figure 2 The function switch: TIG mode MMA mode 7-Pin Socket— — Used for the TIG torch switch only. Figure 3 Function TIG torch switch TIG torch switch Table 4 - 11 - BOSS TIG 160HF¡¢ 200HF Operating Manual... - Page 13 12. Input Power Cable 13. Gas Inlet 14. Ground Screw 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 TIG 160HF¡¢ 200HF Operating Manual...
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Page 14: Weld Parameter Description
TIG 200HF Peak Current 10~160A 10~200A 10~160A 10~200A Welding Current STICK 10~140A 10~160A Pulse Frequency 2Hz/250Hz/OFF 2Hz/250Hz/OFF Down Slope Time 0~5S 0~5S Post-Flow Time Table 6 Weld parameters for TIG HF series - 13 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 15: Set-Up For Mma (Stick) And Gtaw (Tig)
Primary power supply is switched off. CAUTION 2: Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. - 14 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 16: Stick Welding
Argon Gas flow thickness (mm) diameter (mm) diameter (mm) (L/min) 0.3-0.5 1-1.6 5-30 0.5-1.2 1.6-2 10-50 1.2-1.6 1.2-2 1.6-2 10-50 1.2-1.6 1.2-2 1.6-2 30-70 1.6-2.0 60-100 1.6-2.0 7-10 100-200 2.0-2.5 1-15 Table 8 - 15 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 17: Power Supply Controls Indicators And Reatures
Welding currents control— — Uses in adjusting the welding current. Warning indicator— — Red colored light instruction welding machine overload. AC power indicator— — Green colored light instruction power source is normal. Main Power switch. - 16 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 18: Basic Tig Welding Guide
200— 350 Table 11 Filler wire selection guide Notice£º The filler wire diameter specified in Table 11 is a guide only, other diameter wires may be used according to the welding application. - 17 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 19: Shielding Gas Selection
115— 135 100— 125 butt/ corner 140— 165 125— 150 lap/ fillet 160— 175 135— 160 butt/ corner 170— 200 160— 180 lap/ fillet Table 14 DC TIG welding parameters - 18 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 20: Basic Arc Welding Guide
It will weld most problematical jobs such as springs, shafts, 312-16 metals, crack resistance, all broken joins mild steel to stainless and alloy steels. Not hard-to-weld jobs suitable for Aluminum. Table 15 Types of Electrodes - 19 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 21: 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 22 1. Power PCB damage. 1. Replace power PCB. 9. Fan does not run. 2. Fan motor damage. 2. Replace fan motor. 3. Relay PCB damage. 3. Replace relay PCB. Table 16 - 21 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
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Page 23: Tig Welding Problems
B Connect it to the “ ” terminal. C Gas flow incorrectly set, cylinder C Select the right flow rate, change empty or the torch valve is off. cylinders or turn torch valve on. - 22 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 24: Stick Welding Problems
F Wrong electrode for position in which F Use electrodes designed for position welding is done. in which welding is done, otherwise proper control of slag is difficult. Table 18 - 23 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 25: Power Source Problems
C Gas regulator turned off. C Turn gas regulator on. Table 19 Notice: Can move the equipments that the power supply doesn't fixedly mean to link to work with gearing at the some position. - 24 - BOSS TIG 160HF¡¢ 200HF Operating Manual... -
Page 26: 10.0 Parts List
10.0 PARTS LIST - 25 - BOSS TIG 160HF¡¢ 200HF Operating Manual... - Page 27 - 26 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
- Page 28 BOARD,PCB,DIODE (7.820.017-02) BOARD,PCB,DIODE (7.820.017-09) 2HS7061062 HEATSINK LEFT-LOWER 2HS7061063 HEATSINK LEFT-UPPER-A 2HS7061064 HEATSINK LEFT-UPPER-B 2HS7061060 HEATSINK RIGHT-UPPER 2HS7061061 HEATSINK RIGHT-LOWER 2HS7061053 HEATSINK LEFT-LOWER 2HS7061054 HEATSINK LEFT-UPPER-A 2HS7061055 HEATSINK LEFT-UPPER-B 2HS7061051 HEATSINK RIGHT-UPPER - 27 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
- Page 29 COUPLING COIL OVERLAY CONTROL Tig 200HF BOSS 2LAC8807267 OVERLAY CONTROL Tig 160HF BOSS 2LAC8807266 2LAU8803006 LABEL (+ 0 -)65*10 2LAN8808299 LABEL MANUFACTURERS RATING Tig 200HF 2LAN8808298 LABEL MANUFACTURERS RATING Tig 160HF - 28 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
- Page 30 4WTH1A2W100K POTENTIONMETER 2W 100K 4KNX203 SWITCH KNX203 4KNX202 SWITCH KNX202 2FPPT8040001Y PANEL TOP FP8.040.001Y 2FPPT8040000Y PANEL TOP FP8.040.000Y 4HDL00001 HANDLE 2LAW8805000 LABEL WARNING 2LAS8809040 LABEL BOSS 3KITP000107022 ARC STARTER Table 20 - 29 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
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Page 31: 11.0 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. - 30 - BOSS TIG 160HF¡¢ 200HF Operating Manual...
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