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Summary of Contents for Boss ARC 140
- Page 1 MODEL • BOSS ARC 140 • BOSS ARC 160 Operating Manual (Owner’ s Manual) IMPORTANT: Read these instructions before installing, operating, or servicing this system. Second Edition Manual No. B0802...
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Page 3: Table Of Contents
BASIC TROUBLESHOOTING-------------------------------------------------------------------------19 9.01 Check the item and excrescent phenomenon exclusion method---------------------------19 9.02 TIG welding problems---------------------------------------------------------------------------------20 9.03 Stick welding problems--------------------------------------------------------------------------------21 9.04 Power source problems-------------------------------------------------------------------------------22 10.0 PART LIST---------------------------------------------------------------------------------------------------23 11.0 REMARK-----------------------------------------------------------------------------------------------------27 APPENDIX: INTERCONNECT DIAGRAM - 1 - BOSS ARC 140¡¢ 160 Operating Manual... -
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 ARC 140¡¢ 160 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 ARC 140¡¢ 160 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 ARC 140¡¢ 160 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 ARC 140¡¢ 160 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 ARC 140¡¢ 160 Operating Manual... -
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. - 9 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 12: Operator Controls
Negative (-) Socket— — TIG connect the TIG torch/ MMA connect the work lead. Input Power Cable 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. - 10 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 13: Weld Parameter Description
3.02 Weld parameters description Figure 3 BOSS ARC Series front panel with parameter description Parameter Description Welding Current This parameter sets the welding current. Table 4 Weld parameter description for BOSS ARC Series - 11 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 14: Set-Up For Mma (Stick) And Gtaw (Tig)
The operator should use the welding current range values as a guide, and then finally adjust the current setting to suit the application. Figure 4 Set up for BOSS ARC Series 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 15: 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 6 - 13 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 16: Power Supply Controls Indicators And Reatures
POWER SUPPLY CONTROLS INDICATORS AND REATURES Figure 5 BOSS ARC Series front panel 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. -
Page 17: Basic Tig Welding Guide
200— 350 Table 9 Filler wire selection guide Notice£º The filler wire diameter specified in Table 9 is a guide only, other diameter wires may be used according to the welding application. - 15 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 18: 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 12 DC TIG welding parameters - 16 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 19: Basic Arc Welding Guide
It will weld most problematical jobs such as springs, 312-16 metals, crack resistance, all shafts, broken joins mild steel to stainless and alloy steels. hard-to-weld jobs Not suitable for Aluminum. Table 13 Types of Electrodes - 17 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 20: Maintenance
DANGER: HIGH VOLTAGE is present internally even with the control power switch in the OFF position. Before inspecting, cleaning, or servicing, disconnect and lock out input power to the power source. - 18 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 21: Basic Troubleshooting
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: Tig Welding Problems
B Torch lead is disconnected. 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. - 20 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 23: 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 16 - 21 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 24: Power Source Problems
C Gas regulator turned off. C Turn gas regulator on. Table 17 Notice: Can move the equipments that the power supply doesn't fixedly mean to link to work with gearing at the some position. - 22 - BOSS ARC 140¡¢ 160 Operating Manual... -
Page 25: Part List
10.0 PARTS LIST - 23 - BOSS ARC 140¡¢ 160 Operating Manual... - Page 26 - 24 - BOSS ARC 140¡¢ 160 Operating Manual...
- Page 27 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 2HS7061052 HEATSINK RIGHT-LOWER 2FPPM8610005 BRACKET MOUNTING AL 200 2FPPM8610009 BRACKET MOUNTING AL 160 - 25 - BOSS ARC 140¡¢ 160 Operating Manual...
- Page 28 LABEL VOLTAGE INPUT 240V 1PH 2FPB6123007 BASE 200/50 FP6.123.007 2FPB6123009 BASE 160/50 FP6.123.009 2FP7854006 INSULATOR POTENTIONMETER 2FP7854007 INSULATOR POTENTIONMETER 4V2FLEDN01D7R5 LED HOLDER UPPER 4V2FLEDH01D6 LED HOLDER LOWER 2FP7854004 INSULATOR BULKHEAD FRONT 2FP7854008 INSULATOR BULKHEAD REAR - 26 - BOSS ARC 140¡¢ 160 Operating Manual...
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Page 29: 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. - 27 - BOSS ARC 140¡¢ 160 Operating Manual... - Page 30 APPENDIX: ARC 140 (Sensor A) INTERCONNECT DIAGRAM 17AM -105¡æ Thermostat Welding current Ig max 17AM-105¡æ 4XS2 4XS1 1XS10 1XS6 1XS2 1XS7 4X1 4X2 4X3 Thermostat 1XS9 F6x20 1CNY AP5£¨ P WM PCB £© FP7.829.004A 3XS2-6 1XS11 1XS3 over current 3XS2-5 AP1£¨...
- Page 31 APPENDIX: ARC 140 (Sensor B) INTERCONNECT DIAGRAM 17AM-85¡æ Thermostat Welding current Ig max 17AM-105¡æ 4XS2 4XS1 1XS10 1XS6 1XS2 1XS7 4X1 4X2 4X3 Thermostat 1XS9 F6x20 1CNY AP5£¨ P WM PCB£© FP7.829.004A 3XS2-6 1XS11 1XS3 over current 3XS2-5 A P 1£¨ C ontrol PCB £©...
- Page 32 2XS17 yellow 2XS16 FP7.820.002F-01 35A/1KV Black 2XS15 2XS5 2XS14 yellow 2XS13 yellow 2XS12 2XS3 2XS8 2XS9 Black 220V/240V AC AP6£¨ Relay PCB£© FP7.820.000A Main switch ±ê¼Ç ÊýÁ¿ ¸ü¸Äµ¥ºÅ Ç©Ãû 16A/250V - 30 - BOSS ARC 140¡¢ 160 Operating Manual...
- Page 33 2XS16 FP7.820.002F-01 35A/1KV Black 2XS15 2XS5 r e d 2XS14 yellow 2XS13 yellow 2XS12 2XS3 2XS8 2XS9 Black 220V/240V AC AP6£¨ R elay PCB£© FP7.820.000A Main switch ±ê¼Ç ÊýÁ¿ ¸ü¸Äµ¥ºÅ 16A/250V - 31 - BOSS ARC 140¡¢ 160 Operating Manual...
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