BOSSCO ARC 160 Bedienungsanleitung

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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BOSS ARC140、160 Operating Manual

CONTENTS

SYMBOL LEGEND---------------------------------------------------------------------------------------------------2

STATEMENT OF WARRANTY------------------------------------------------------------------------------------3

1.0 GENERAL INFORMATION-------------------------------------------------------------------------------4

1.01 Notes, Cautions and Warnings------------------------------------------------------------------------4

1.02 Important Safety Precautions--------------------------------------------------------------------------4

1.03 Transporting methods-----------------------------------------------------------------------------------6

2.0 INSTALLATION RECOMMENDATION----------------------------------------------------------------7

2.01 Electrical Input Connections---------------------------------------------------------------------------8

2.02 Specifications----------------------------------------------------------------------------------------------9

2.03 Duty cycle--------------------------------------------------------------------------------------------------9

3.0 OPERATOR CONTROLS-------------------------------------------------------------------------------10

3.01 BOSS ARC Series controls---------------------------------------------------------------------------10

3.02 Weld parameter description--------------------------------------------------------------------------11

4.0 SET-UP FOR MMA(STICK) AND GTAW (TIG)----------------------------------------------------12

4.01 Stick welding---------------------------------------------------------------------------------------------13

4.02 DC TIG welding-----------------------------------------------------------------------------------------13

5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------14

6.0 BASIC TIG WELDING GUIDE--------------------------------------------------------------------------15

6.01 Electrode Polarity---------------------------------------------------------------------------------------15

6.02 Tungsten Electrode Current Ranges---------------------------------------------------------------15

6.03 Tungsten Electrode Types----------------------------------------------------------------------------15

6.04 Guide for Selecting Filler Wire Diameter----------------------------------------------------------15

6.05 Shielding gas selection--------------------------------------------------------------------------------16

6.06 TIG welding parameters for low carbon & low alloy steel pipe-------------------------------16

6.07 Welding parameters for steel------------------------------------------------------------------------16

7.0 BASIC ARC WELDING GUIDE------------------------------------------------------------------------17

7.01 Electrode polarity---------------------------------------------------------------------------------------17

7.02 Effects of stick welding various materials---------------------------------------------------------17

8.0 MAINTENANCE--------------------------------------------------------------------------------------------18

9.0 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

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BOSS ARC140、160 Operating Manual

SYMBOL LEGEND

AAmperage

Stick (SMAW)

VVoltage

Pulse Current Function

(GTAW)

Hz Hertz (frequency)

tSpot Time (GTAW)

SEC Seconds

Remote outputs control

(Panel/Remote)

%Percent

Remote Function

DC (Direct Current)

Arc Control (SMAW)

AC (Alternating Current)

2Gas Post-Flow Time

2T (GTAW)

t1Gas Pre-Flow Time

4T (GTAW)

VRD Voltage Reduction

Device Circuit

Repeat Function (GTAW)

—Negative

Spot Function (GTAW)

+Positive

High Frequency Starting

(GTAW)

Gas Input

Lift Start （GTAW）

Gas Output

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BOSS ARC140、160 Operating Manual

STATEMENT OF WARRANTY

LIMITED WARRANTY: "BOSS" warrants to customers of its authorized distributors hereafter "BOSS" that its products will be

free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period

applicable to theBOSS products as stated below, BOSS shall, upon notification thereof and substantiation that the product has

been stored, installed, operated, and maintained in accordance withBOSS’sspecifications,instructions, recommendations and

recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by

suitable repair or replacement, at BOSS ‘s sole option, of any components or parts of the product determined by BOSS to be

defective.

The BOSS COMPANY MAKESNO OTHER WARRANTY,EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND

IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS

FOR ANY PARTICULARPURPOSE.

LIMITATION OF LIABILITY: BOSS shall not under any circumstances be liable for special, indirect or consequential damages,

such as, but not limited to, lost profits and business interruption. The remedies of the Purchaser set forth herein are exclusive

and the liability of BOSS with respect to any contract, or anything done in connection therewith such as the performance or

breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by BOSS whether

arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein,

exceed the price of the goods upon which such liability is based. No employee, agent, or representative of BOSS is authorized

to change this warranty in any way or grant any other warranty.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED

WHICH IN BOSS’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY BOSS PRODUCT.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY

NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to

the Purchaser. Notwith standing the foregoing, in no event shall the warranty period extend more than the time stated plus one

year from the dateBOSS delivered the product to the authorized distributor.

POWER SUPPLIES POWER SUPPLIES & WIRE FEEDERS

MAIN POWER MAGNETICS (STATIC& ROTATING) 1YEAR

ORIGINAL MAIN POWER RECTIFIER 1YEAR

POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 1YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,

SOLENOIDS, PUMPS, SWITCHES, MOTORS

Warranty repairs or replacement claims under this limited warranty must be submitted toBOSS by an authorizedBOSS repair

facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind willbepaidunder

this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the

Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous BOSS

warranties.

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BOSS ARC140、160 Operating Manual

1.0 GENERAL INFORMATION

1.01 Notes,Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These

highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in

efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND

HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions

before using the equipment. Call your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the Arc welding or cutting process can be dangerous and hazardous to

your health.

lKeep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

lUse an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

lThe kinds of fumes and gases from the arc welding/cutting depend on the kind of metal being used,

coatings on the metal, and the different processes. You must be very careful when cutting or welding

any metals which may contain one or more of the following:

Antimony Arsenic Barium Beryllium Cadmium Chromium Cobalt Copper Lead

ManganeseMercury Nickel Selenium Silver Vanadium

lAlways read the Material Safety Data Sheets (MSDS) that should be supplied with the material you

are using. These MSDSs will give you the information regarding the kind and amount of fumes and

gases that may be dangerous to your health.

lUse special equipment, such as water or down draft welding/cutting tables, to capture fumes and

gases.

lDo not use the welding torch in an area where combustible or explosive gases or materials are

located.

lPhosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove

all sources of these vapors.

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BOSS ARC140、160 Operating Manual

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy.

This electric energy can cause severe or fatal shock to the operator or others in the workplace.

lNever touch any parts that are electrically “live” or “hot.”

lWear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding

circuit.

lRepair or replace all worn or damaged parts.

lExtra care must be taken when the workplace is moist or damp.

lInstall and maintain equipment according to NEC code, refer to relative standards

lDisconnect power source before performing any service or repairs.

lRead and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the arc weld.

lBe sure there is no combustible or flammable material in the workplace. Any material that cannot be

removed must be protected.

lVentilate all flammable or explosive vapors from the workplace.

lDo not cut or weld on containers that may have held combustibles.

lProvide a fire watch when working in an area where fire hazards may exist.

lHydrogen gas may be formed and trapped under aluminum workpieces when they are cut

underwater, or while using a water table. Donot cut aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Arc welding/cutting processes can cause noise levels to exceed

safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

lTo protect your hearing from loud noise, wear protective ear plugs and/ or ear muffs. Protect others

in the workplace.

lNoise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

ARC WELDING RAYS

Arc Welding/ Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces

very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are

not properly protected.

lTo protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

lWear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

lKeep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

lProtect others in the work area from the arc rays. Use protective booths, screens or shields.

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BOSS ARC140、160 Operating Manual

1.03 Transporting methods

These units are equipped with a handle for carrying purposes.

WARNING: ELECTRIC SHOCK can kill.

DO NOT TOUCHlive electrical parts. Disconnect input power conductors from de-energized supply

line before moving the welding power source.

WARNING: FALLING EQUIPMENT can cause serious personal injury and

equipment damage.

lLift unit with handle on top of case.

lUse handcart or similar device of adequate capacity.

lIf using a fork lift vehicle, place and secure unit on a proper skid before transporting.

-7 -

BOSS ARC140、160 Operating Manual

2.0 INSTALLATION RECOMMENDATION

Installation Environment

BOSS ARC Series is designed for use in hazardous environments.

Examples of environments with increased hazardous environments are-

In locations in which freedom of movement is restricted, so that the operator is forced to perform the work

in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts; In locations which

are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or

accidental contact by the operator, or in wet or damp hot locations where humidity or perspiration

considerable reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive parts in

the near vicinity of the operator, which can cause increased hazard, have been insulated.

Installation Location

Be sure to locate the welder according to the following guidelines:

lIn areas, free from moisture and dust.

lIn areas, free from oil, steam and corrosive

gases.

lIn areas, not exposed to direct sunlight or rain.

lAmbient temperature: between -10 degrees C

to 40 degrees C.

lIn areas, not subjected to abnormal vibration or

shock.

lPlace at a distance of 304.79mm or more from

walls or similar that could restrict natural airflow

for cooling.

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 circuit size Current & Duty Cycle

Model Primary

supply lead

size TIG STICK TIG STICK

BOSS ARC 140 Minimum

5mm2220V/19.5A

240V/17.9A

220V/27A

240V/24.8A

140A/15.6V@60%

125A/15V@100% 140A/25.6V@60%

110A/24.4V@100%

BOSS ARC 160 Minimum

6mm2220V/22A

240V/20.2A

220V/33.5A

240V/30.7A

160A/16.4V@100%

160A/26.4V@60%

125A/25V@100%

Table 1 Primary current circuit sizes to achieve maximum current

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BOSS ARC140、160 Operating Manual

2.01 Electrical Input Connections

WARNING: ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present

after removal of input power.

DO NOT TOUCH live electrical parts

SHUT DOWN welding power source, disconnect input power employing lockout/ tagging procedures.

Lockout/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses

from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding power source from a single phase 50/ 60 Hz, AC power supply. The input voltage must

match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the

local electric utility for information about the type of electrical service available, how proper connections

should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power

from the welding power supply whenever necessary to inspect or service the unit.

According to Table 1 and below as a guide to select line fuses for the disconnect switch.

Input Voltage Fuse Size

220/240V AC 50 Amps

Table 2

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

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