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 ARC 140、160 Operating Manual
CONTENTS
SYMBOL LEGEND---------------------------------------------------------------------------------------------------2
STATEMENT OF WARRANTY------------------------------------------------------------------------------------3
1.0 GENERAL INFORMATION-------------------------------------------------------------------------------4
1.01 Notes, Cautions and W arnings------------------------------------------------------------------------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 w elding---------------------------------------------------------------------------------------------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 w elding 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 w elding 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 w elding problems---------------------------------------------------------------------------------20
9.03 Stick w elding 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 ARC 140、160 Operating Manual
SYMBOL LEGEND
A
Amperage
Stick (SMAW)
V
Voltage
Pulse Current Function
(GTAW)
Hz
Hertz (frequency)
t
Spot Time (GTAW)
SEC
Seconds
Remote outputs control
(Panel/Remote)
%
Percent
Remote Function
DC (Direct Current )
Arc Control (SMAW)
AC (Alternating Current )
t
2
Gas Post-Flow Time
2T (GTAW)
t
1
Gas 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 ARC 140、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 the BOSS products as stated below, BOSS shall, upon notification thereof and substantiation that the product has
been stored, installed, operated, and maintained in accordance with BOSS’s specifications, 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 MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMIT ED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE.
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. Not with standing the foregoing, in no event shall the warranty period extend more than the time stated plus one
year from the date BOSS 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 to BOSS by an authorized BOSS repair
facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind wi ll be paid under
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 ARC 140、160 Operating Manual
1.0 GENERAL INFORMATION
1.01 Notes, Cautions and W arnings
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.
l Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
l Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
l The 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
Manganese Mercury Nickel Selenium Silver Vanadium
l Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you
are using. The se MSDSs will give you the information regarding the kind and amount of fumes and
gases that may be dangerous to your health.
l Use special equipment, such as water or down draft welding/cutting tables, to capture fumes and
gases.
l Do not use the welding torch in an area where combustible or explosive gases or materials are
located.
l Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove
all sources of these vapors.
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BOSS ARC 140、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.
l Never touch any parts that are electrically “live” or “hot.”
l Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding
circuit.
l Repair or replace all worn or damaged parts.
l Extra care must be taken when the workplace is moist or damp.
l Install and maintain equipment according to NEC code, refer to relative standards
l Disconnect power source before performing any service or repairs.
l Read 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.
l Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
l Ventilate all flammable or explosive vapors from the workplace.
l Do not cut or weld on containers that may have held combustibles.
l Provide a fire watch when working in an area where fire hazards may exist.
l Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut
underwater, or while using a water table. Do not 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.
l To protect your hearing from loud noise, wear protective ear plugs and/ or ear muffs. Protect others
in the workplace.
l Noise 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.
l To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
l Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
l Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
l Protect others in the work area from the arc rays. Use protective booths, screens or shields.
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BOSS ARC 140、160 Operating Manual
1.03 Transporting methods
These units are equipped with a handle for carrying purposes.
WARNING: ELECTRIC SHOCK can kill.
DO NOT TOUCH live 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.
l Lift unit with handle on top of case.
l Use handcart or similar device of adequate capacity.
l If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
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BOSS ARC 140、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 tha t 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:
l In areas, free from moisture and dust.
l In areas, free from oil, steam and corrosive
gases.
l In areas, not exposed to direct sunlight or rain.
l Ambient temperature: between -10 degrees C
to 40 degrees C.
l In areas, not subjected to abnormal vibration or
shock.
l Place 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
5mm2
220V/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
6mm2
220V/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 ARC 140、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 we lding 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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BOSS ARC 140、160 Operating Manual
2.02 Specifications
MODEL BOSS ARC 140 BOSS ARC 160
Input voltage and frequency and phases
220/240V 50/60Hz 1ph 220/240V 50/60Hz 1ph
TIG 4.3KVA 4.8KVA
KVA @ max output
STICK 6.0KVA 7.4kVA
Max current 140A 160A
Output current range
10~140A 10~160A
Open circuit voltage 56/61V 56/61V
Duty cycle at 40℃ 60% 60%
Weight 9.5kg 12kg
Dimensions (mm)
370×150×245 420×160×265
Table 3
2.03 Duty cycle
The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be
operated at a given output without causing overheating and damage to the unit. If the welding amperes
decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty
cycle will decrease.
WARNING: Exceeding the duty cycle ratings will cause the thermal overload
protection circuit to become energized and shut down the output until has cooled
to normal operating temperature
Continually exceeding the duty cycle ratings
can cause damage to the welding power source.
NOTICE：
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.
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BOSS ARC 140、160 Operating Manual
3.0 OPERATOR CONTROLS
3.01 BOSS ARC SERIES controls
Figure 2
1. Welding Current Control——U sed for regulating to welding current.
2. Warning Indicator
3. AC Power Indicator
4. Main Power Switch
5. Positive (+) Socket——TIG connect the work lead/ MMA connect the electrode holder.
6. Negative (-) Socket——TIG connect the TIG torch/ MMA connect the work lead.
7. Input Power Cable
8. 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.
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BOSS ARC 140、160 Operating Manual
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
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BOSS ARC 140、160 Operating Manual
4.0 SET-UP FOR MMA (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the w elding power source, i.e. connect work lead
directly to work piece and welding cable is used to electrode holder. Wide safety margins provided by the coil
design ensure that the w elding power source will withstand short-term overload without adverse effects. The
welding current range values should be used as a guide only. Current delivered to the arc is dependent on the
welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding
current at any one setting would vary according to the type of electrode in use. 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.
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.
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BOSS ARC 140、160 Operating Manual
4.01 Stick welding
l Connect work lead to negative terminal.
l Connect electrode lead to positive terminal.
l Switch machine on.
l Set welding current control (see table 5).
Workpiece thickness mm 0.5-2.0 2.0-5.0 5.0-7.0
Electrode diameter mm 1.0-2.0 2.0-3.2 3.2-4.0
Welding current（A ） 10-50 50-150 150-250
Table 5
4.02 DC TIG welding
l Connect work lead to positive terminal.
l Connect TIG torch to negative terminal.
l Switch machine on.
l Set welding current control (see table 6).
l Use TIG torch with value control.
Workpiece
thickness (mm)
Tungsten
diameter (mm)
Welding current
(A)
Filler wire
diameter (mm)
Argon Gas flow
(L/min)
0.3-0.5 1-1.6 5-30 3-8
0.5-1.2 1.6-2 10-50 1.2-1.6 4-8
1.2-2 1.6-2 10-50 1.2-1.6 4-8
1.2-2 1.6-2 30-70 1.6-2.0 6-9
2-4 2-4 60-100 1.6-2.0 7-10
4-6 3-4 100-200 2.0-2.5 1-15
Table 6
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BOSS ARC 140、160 Operating Manual
5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES
Figure 5 BOSS ARC Series front panel
1. Welding currents control——U ses in adjusting the welding current.
2. Warning indicator ——Red colored light instruction welding machine overload.
3. AC power indicator——Green colored light instruction power source is normal.
4. Main Power switch.
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BOSS ARC 140、160 Operating Manual
6.0 BASIC TIG WELDING GUIDE
6.01 Electrode Polarity
Connect the TIG torch to the - / torch terminal and the work lead to the + / work terminal for direct current
straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows
limited wear of the electrode since 70% of the heat is concentrated at the work piece.
6.02 Tungsten Electrode Current Ranges
Electrode Diameter (mm) DC current (A )
1.0 30— 60
1.6 60— 115
2.4 100— 165
3.2 135— 200
4.0 190— 280
4.8 250— 340
Table 7 Current ranges for varies tungsten electrode sizes
6.03 Tungsten Electrode Types
Tungsten type
(Ground finish)
Welding Application Features
Color
code
Thoriated 2%
DC welding of mild steel, stainless
steel and copper
Excellent arc starting, Long life, high
current carrying capacity
Red
Ceriated 2%
DC welding of mild steel, stainless
steel, copper, aluminium, magnesium
and their alloys
Longer Life, More stable arc, Easier
starting, Wider current range,
N arrower more concentrated arc
Grey
Table 8 Tungsten electrode types
6.04 Guide for Selecting F iller Wire Diameter
Filler wire diameter DC current range (Amps)
1.6 20— 90
2.4 65— 115
3.2 100— 165
4.8 200— 350
Table 9 Filler wire selection guide
Notice：
The filler wire diameter specified in Table 9 is a guide only, other diameter wires may be used
according to the welding application.
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BOSS ARC 140、160 Operating Manual
6.05 Shielding gas selection
Alloy Shielding gas
Aluminium & alloys Argon
Carbon steel Argon
Stainless steel Argon
Nickel alloy Argon
Copper Argon
Titanium Argon
Table 10 Shield gas selection
6.06 TIG welding parameters for low carbon & low alloy steel p ipe
Tungsten type &
diameter
Current range DC
(Amperes)
Filler rod for root pass
Joint preparation
Thoriated 2%
3/32” (2.4mm)
120— 170 Yes
Thoriated 2%
3/32” (2.4mm)
100— 160 Yes
Thoriated 2%
3/32” (2.4mm)
90— 130 No
Table 11 TIG welding parameters for low carbon & low alloy steel pipe
6.07 Welding parameters for steel
Base metal
thickness
(mm)
DC current
for mild
steel (A )
DC current
for stainless
steel (A )
Tungsten
diameter
(mm)
Filler rod
diameter (if
require) (mm)
Argon gas
flow rate
(litres/min)
Joint type
1.0
35— 45
40— 50
20— 30
25— 35
1.0 1.6 5— 7
butt/ corner
lap/ fillet
1.2
45— 55
50— 60
30— 45
35— 50
1.0 1.6 5— 7
butt/ corner
lap/ fillet
1.6
60— 70
70— 90
40— 60
50— 70
1.6 1.6 7
butt/ corner
lap/ fillet
3.2
80— 100
90— 115
65— 85
90— 110
1.6 2.4 7
butt/ corner
lap/ fillet
4.8
115— 135
140— 165
100— 125
125— 150
2.4 3.2 10
butt/ corner
lap/ fillet
6.4
160— 175
170— 200
135— 160
160— 180
3.2 4.0 10
butt/ corner
lap/ fillet
Table 12 DC TIG welding parameters
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BOSS ARC 140、160 Operating Manual
7.0 BASIC ARC W ELDING GUIDE
7.01 Electrode polarity
Stick electrodes are generally connected to the “+” terminal and the work lend to the “-“ terminal but if in
doubt consult the electrode manufacturers literature.
7.02 Effects of stick welding various materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld
area, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone
and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using
higher current settings, using larger electrodes size, short runs for larger electrode deposits or tempering in a
furnace.
Manganese steels
The effect on manganese steel slow of cooling from high temperature is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip
welding to distribute the heat.
Cast iron
Most types of cast iron, expect white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by gas held in this type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of copper, so making preheating of heavy
sections necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc welding electrodes are classified into a number of groups depending on their applications. There are
a great number of electrodes used for specialized industrial purposes, which are not of particular interest for
everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for
welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast
majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of
welding machines.
Metals being joined Electrode Comments
mild steel 6013
Ideal electrodes for all general purpose work. Features
include out standing operator appeal, easy arc starting
and low spatter.
mild steel 7014
All positional electrodes for use on mild and galvanized
steel furniture, plates, fences, gates, pipes and tanks etc.
Especially suitable for vertical-down welding.
cast iron
nickel 99%
Suitable for joining all cast irons except white cast iron.
stainless steel 318L-16
High corrosion resistance. Ideal for dairy work, etc. On
stainless steels.
copper, bronze, brass etc.
bronze
5.7ERCUSI-A
Easy to use electrode for marine fittings, water taps and
valves, water trough float arms, etc. Also for joining copper
to steel and for bronze overlays on steel shafts.
high alloy steels, dissimilar
metals, crack resistance, all
hard-to-w eld jobs
312-16
It will weld most problematical jobs such as springs,
shafts, broken joins mild steel to stainless and alloy steels.
Not suitable for Aluminum.
Table 13 Types of Electrodes
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BOSS ARC 140、160 Operating Manual
8.0 MAINTENANCE
If this equipment does not operate properly, stop work immediately and investigate the cause of the
malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical
work must be performed by an electrician or other person properly trained in servicing electrical equipment.
Do not permit untrained persons to inspect, clean or repair this equipment. Use only recommended
replacement parts when servicing this machine.
Periodically clean the inside of the welding power source by using clean dry compressed air of not over
25psi as normal preventive maintenance. At the time of the cleaning, a full inspection of the welding machine
and setup should be performed. Check warning labels on the machine for readability; replace if necessary.
Check input and output connections as well as frame ground connections to the machine to insure that they
are tight and the wires are not frayed or overheated. Inspect internal wiring of machine for loose or frayed
connections; tighten or repair as necessary. It would also be advisable to check connections to wire feeders,
fixtures, etc., at this time. Any damaged cable or hoses should be replaced.
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.
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BOSS ARC 140、160 Operating Manual
9.0 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 w elding power source must be returned to an
accredited BOSS service agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or
knowledge.
9.01 Check the item and excrescent phenomenon exclusion method
Troubleshooting Guide
Fault Cause Remedy
1. The AC power indicator light is
not lit and welding arc can not
be established.
1. No power input or main power
switches damage.
2. Primary fuse is blown.
3. Indicator damage.
4. Relay PCB damage (for ARC 160).
5. Indicator light is open circuit.
1. Check input power or replace
main power switch.
2. Replace primary fuse.
3. Replace indicator light.
4. Replace relay PCB.
5. Replace indicator light.
2. The AC power indicator light on
and welding arc can not be
established.
1. Input voltage unstable.
2. Diode PCB damage.
1. Connect stabilizer or reset power
switch.
2. Replace diode PCB.
3. The warning indicator light on.
1. Over load.
2. MOSFET dama ge.
1. Reduce current or wait moment.
2. Replace MOSFET.
4. MMA (STICK) mode no circuit
output.
1. Function switch select to the MMA
mode position.
2. Relay PCB damage.
3. MOSFET damage.
1. Select to MMA mode.
2. Replace relay PCB.
3. Replace MOSFET.
5. MMA (STICK) mode unstable
welding arc.
1. Power PCB damage.
2. Diode PCB damage.
3. Control PCB damage.
1. Replace power PCB.
2. Replace diode PCB.
3. Replace control PCB.
6. Fan does not run.
1. Power PCB damage.
2. Fan motor damage.
3. Relay PCB damage.
1. Replace power PCB.
2. Replace fan motor.
3. Replace relay PCB.
Table 14
- 20 -
BOSS ARC 140、160 Operating Manual
9.02 TIG welding problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description Possible Cause Remedy
1. Excessive bead build-up
or poor penetration or
poor fusion at edges of
weld.
Welding current is too low.
Increases weld current, and/ or faulty
joint preparation.
2. Weld bead too wide and
flat or undercut at edges
of weld or excessive
burn through.
Welding current is too high. Decreases weld current.
3. Weld bead too small or
insufficient penetration
or ripples in bead are
widely spaced apart.
Travel speed too fast. Reduce weld speed.
4. Weld bead too wide or
excessive bead build up
or excessive penetration
in butt joint.
Travel speed too low. Increase travel speed.
5. Uneven leg length in
fillet joint.
Wrong placement of filler rod. Re-position filler rod.
6. Dirty weld pool.
A Electrode contaminated through
contact with work piece or filler rod
material.
B Gas contaminated with air.
A Clean the electrode by grinding off
the contaminates.
B Check gas lines for cuts and loose
fitting or change gas cylinder.
7. Electrode melts or
oxidizes when an arc is
struck.
A Electrode is connected to the “+ ”
terminal.
B No gas flowing to welding region.
C Torch is clogged with dust.
D Gas hose is cut.
E Gas passage contains impurities.
F Gas regulator turned off.
G Torch valve is turned off.
H The electrode is too small for the
welding current.
A Connected the electrode to the “-”
terminal.
B Check the gas lines for kinks or
breaks and gas cylinder con tents.
C Clean torch.
D Replace gas hose.
E Dismantle a soft tube from the
torch then raise gas pressure and
blow out impurities.
F Turn on.
G Turn on.
H Increase electrode diameter or
reduce the welding current.
8. Poor weld finish. Inadequate shielding gas.
Increase gas flow or check gas line for
gas flow problems .
9. Arc flutters during TIG
welding.
A Tungsten electrode is too large for
the welding current.
B Absence of oxides in the weld pool.
A
Select the right size electrode.
Refer to basic TIG w elding guide.
B Refer basic TIG w elding guide for
ways to reduce arc flutter.
10. Welding arc can not be
established.
A Work clamp is not connected to the
work piece or the work/ torch leads
are not connected to the right
welding terminals.
B Torch lead is disconnected.
C Gas flow incorrectly set, cylinder
empty or the torch valve is off.
A Connect the work clamp to the
work piece or connect the work/
torch leads to the right welding
terminals.
B Connect it to the “−” terminal.
C Select the right flow rate, change
cylinders or turn torch valve on.
- 21 -
BOSS ARC 140、160 Operating Manual
11. Arc start is not smooth.
A Tungsten electrode is too large for
the welding current.
B The wrong electrode is being used
for the welding job.
C Gas flow rate is too high.
D Incorrect shielding gas is being
used.
E Poor work clamp connection to
work piece.
A Select th
e right size electrode.
Refer to basic TIG w elding guide.
B Select the right electrode type.
Refer to basic TIG w elding guide
C Select the correct rate for the
welding job.
D
Select the right shielding gas.
Refer to Basic TIG Welding Guide.
E Improve connectio n to work piece.
Table 15
9.03 Stick welding problems
Description Cause Remedy
1 Gas pockets or
voids in weld metal
(Porosity).
A Electrodes are damp .
B Welding current is too large.
C Surface impurities such as: oil,
grease, paint, etc.
A Dry electrodes befo re use.
B Reduce welding current.
C Clean joint before welding.
2 Crack occurring in
weld metal soon
after solidification
commences.
A Rigidity of joint.
B Insufficient throat thickness.
C Cooling rate is too high.
A Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow greater
build up in throat.
C Preheat plate and cool slowly.
3 A gap is left by
failure of the weld
metal to fill the root
of the weld.
A Welding current is too low.
B Electrode too large for joint.
C Insufficient gap.
D Incorrect sequence.
A Increase welding current.
B Use smaller diameter electrode.
C Allow wider gap.
D Use correct build-up sequence.
4 Portions of the weld
run do not fuse to
the surface of the
metal or edge of the
joint.
A Small electrodes used on heavy cold
plate.
B Welding current is too low.
C Wrong electrode angle.
D Travel speed of electrode is too high.
E Scale or dirt on joint surface.
A Use larger electrodes and preheat
the plate.
B Increase welding current.
C Adjust angle so the welding is
directed more into the base metal.
D Reduce travel speed of electrode.
E Clean surface before welding.
5 Non-metallic
particles are trapped
in the weld metal
(slag inclusion) .
A Non-metallic particles may be trapped
in undercut from previous run.
B Joint preparation too restricted.
C Irregular deposits allow slag to be
trapped.
D Lack of penetration with slag trapped
beneath weld bead .
E Rust or mill scale is preventing full
fusion.
F Wrong electrode for position in which
welding is done.
A If bad undercut is present, clean slag
out and cover with a run from a
smaller diameter electrode.
B Allow for adequate penetration and
room for cleaning out the slag.
C If very bad, chip or grind out
irregularities.
D Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E Clean joint before welding.
F Use electrodes designed for position
in which welding is done, otherwise
proper control of slag is difficult.
Table 16
- 22 -
BOSS ARC 140、160 Operating Manual
9.04 Power source problems
Description Possible Cause Remedy
1 The welding arc can not be
established.
A The Primary supply voltage has not
been switched on.
B The w elding power source switch is
switched off.
C Loose connections internally.
A Switch on the primary
supply voltage .
B Switch on the w elding
power source.
C Have an accredited BOSS
service agent repair the
connection.
2 Maximum output welding
current can not be
achieved with nominal
Mains supply voltage.
Defective control circuit.
Have an accredited BOSS
service agent inspect then
repair the welder.
3 Welding current reduces
when welding.
Poor work lead connection to the work
piece.
Ensure that the work lead has a
positive electrical connection to
the work piece.
4 No gas flow when the torch
trigger switch is depressed.
A Gas hose is cut.
B Gas passage contains impurities.
C Gas regulator turned off.
A Replace gas hose.
B Disconnect gas hose from
the rear of power source
then raise gas pressure and
blow out impurities.
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.
- 23 -
BOSS ARC 140、160 Operating Manual
10.0 PARTS LIST
- 24 -
BOSS ARC 140、160 Operating Manual
- 25 -
BOSS ARC 140、160 Operating Manual
Figure 6
QTY.
ARC 140 ARC 160
Sequence
Order No Name
Sensor A Sensor B Sensor A Sensor B
1 3KITP000505020 BOARD,PCB,CONTROL (7.820.514-09) 1 1
1 3KITP000502002 BOARD,PCB,CONTROL (7.820.514-10) 1 1
2 3KITP000106101 OUTPUT MMA160H 1
2 OUTPUT MMA160H(SENSOR) 1
2 3KITP000106000 OUTPUT MMA140 1
2 OUTPUT MMA140 (SENSOR) 1
2-1 3KITP000506011 BOARD,PCB,MOSFET (7.820.005B) 1 1
2-1 3KITP000106011 BOARD,PCB,MOSFET (7.820.016A) 1 1
2-2 3KITP000506021 BOARD,PCB,DIODE (7.820.010A-02) 1
2-2 3KITP000506035 BOARD,PCB,DIODE (7.820.010A-11) 1
2-2 3KITP000106022 BOARD,PCB,DIODE (7.820.017-02) 1
2-2 BOARD,PCB,DIODE (7.820.017-09) 1
2-3 2HS7061062 HEATSINK LEFT -LOWER 1 1
2-4 2HS7061063 HEATSINK LEFT -UPPER-A 1 1
2-5 2HS7061064 HEATSINK LEFT -UPPER-B 1 1
2-6 2HS7061060 HEATSINK RIGHT -UPPER 1 1
2-7 2HS7061061 HEATSINK RIGHT -LOWER 1 1
2-3 2HS7061053 HEATSINK LEFT -LOWER 1 1
2-4 2HS7061054 HEATSINK LEFT -UPPER-A 1 1
2-5 2HS7061055 HEATSINK LEFT -UPPER-B 1 1
2-6 2HS7061051 HEATSINK RIGHT -UPPER 1 1
2-7 2HS7061052 HEATSINK RIGHT -LOWER 1 1
2-8 2FPPM8610005 BRACKET MOUNTING AL 200 1 1
2-8 2FPPM8610009 BRACKET MOUNTING AL 160 1 1
- 26 -
BOSS ARC 140、160 Operating Manual
2-9 3KITP000106030 THERMOSTAT (Inside) 1 1 1 1
2-10 4VQK2SK2837 MOSFET 2837 12 12 16 16
2-11 4V2HMM20FU020BC812 DIODE ULTRA FAST RECOVERY 12 12 16 16
2-12 4LZQ4X2X5 HOSE FERRITE 4*2*5 36 36 48 48
2-13 2FP8647002 INSULATOR II 16 16 20 20
2-14 2FP8647003 INSULATOR I 1 1 1 1
2-15 2FPBM8610016 BRACKET,HEATSINK MOUNTING 1 1
2-16 2FPBM8610017 BRACKET,HEATSINK MOUNTING 1 1
2-17 2FPBM8610021 BRACKET,HEATSINK MOUNTING I 2 2
2-18 2FPBM8610022 BRACKET,HEATSINK MOUNTING II 2 2
2-15 2FPBM8610000 BRACKET,HEATSINK MOUNTING 1 1
2-16 2FPBM8610001 BRACKET,HEATSINK MOUNTING 1 1
2-17 2FPBM8610019 BRACKET,HEATSINK MOUNTING I 2 2
2-18 2FPBM8610020 BRACKET,HEATSINK MOUNTING II 2 2
2-19 2FPPP8610117 BRACKET,MOSFET/DIODE (8.610.117) 9 9 16 16
2-20 2FPPP8610118 BRACKET,MOSFET/DIODE (8.610.118) 2 2
2-21 2FP7840003 INSULATOR,HEATSINK 1 1
2-21 2FP7840002 INSULATOR,HEATSINK 1 1
2FP7854011 SPACER,NYLON 凹 D5 8 8 8 8
2-22
4BFTDQ001D5 SPACER,NYLON 凸 D5 8 8 8 8
2FP7854015 SPACER,NYLON 凹 D4 2 2 2 2
2-23
4BFTDQ003D3BK SPACER,NYLON 凸 D3 2 2 2 2
2-24 4ABKBPC3510 RECTIFIER 2 2 2 2
3 3KITP000107015 BOARD,PCB,POWER MMA (7.820.002F-01) 1 1 1 1
4 3KITP000509000 BOARD,PCB,RELAY-INPUT (7.820.000A) 1 1
8 3KITP002801010 BOARD,PCB,SENSOR(7.828.019A-02)(Inside)
1 1
9 3BB7725033 BUS BAR,POSITIVE 1 1
9 3BB7725032 BUS BAR,POSITIVE 1 1
10 3EER10002 COUPLING COIL 1 1
10 3EER10001 COUPLING COIL 1 1
11 2LAC8807268 OVERLAY CONTROL ARC 160 BOSS 1 1
11 OVERLAY CONTROL ARC 140 BOSS 1 1
12 2LAU8803005 LABEL (+ -)65*10 1 1 1 1
13 2LAN8808300 LABEL MANUFACTURERS RATING ARC 160 1 1
13 LABEL MANUFACTURERS RATING ARC 140 1 1
14 2LAM8800003 LABEL GROUND 1 1 1 1
16 2LAM8800001 LABEL VOLTAGE INPUT 240V 1PH 1 1 1 1
17 2FPB6123007 BASE 200/50 FP6.123.007 1 1
17 2FPB6123009 BASE 160/50 FP6.123.009 1 1
2FP7854006 INSULATOR POTENTIONMETER 2 2 2 2
20
2FP7854007 INSULATOR POTENTIONMETER 2 2 2 2
4V2FLEDN01D7R5 LED HOLDER UPPER 2 2 2 2
21
4V2FLEDH01D6 LED HOLDER LOWER 2 2 2 2
23 2FP7854004 INSULATOR BULKHEAD FRONT 2 2 2 2
24 2FP7854008 INSULATOR BULKHEAD REAR 2 2 2 2
- 27 -
BOSS ARC 140、160 Operating Manual
25 4SXJPG13R5 BUSHING,STRAIN RELIEF PG13.5 1 1 1 1
26 2GS50CC001FP RECEPTACLE,TWIST LOCK(FEMALE) POWER
2 2 2 2
27 4KCD221BK SWITCH 1 1 1 1
28 4KYZPN8D24 KNOB 1 1 1 1
30 4FANCA1238 FAN COVER 1 1 1 1
31 2FP8647000-1 CAP PROTECTION 2 2 2 2
32 4JFT20X27 MOUNT NPRN JJ30 4 4 4 4
33 4FAN001SA1238 FAN 1 1 1 1
34 2PST8634001 INSULATOR FAN 1 1 1 1
36 481CC2KV103 CAPACITOR 3KV103 1 1 1 1
4V2FDLEDD5GN LED GN 2 2 2 2
38
4V2FDLEDS01D5 LED BASE 2 2 2 2
4V2FDLEDD5RDGN LED RD/GN 2 2 2 2
39
4V2FDLEDD5X7 LED BASE 2 2 2 2
40 4WTH1A2W1K POTENTIONMETER 2W 1K 1 1 1 1
47 2FPPT8040001Y PANEL TOP FP8.040.001Y 1 1
47 2FPPT8040000Y PANEL TOP FP8.040.000Y 1 1
48 4HDL00001 HANDLE 1 1 1 1
49 2LAW8805000 LABEL WARNING 1 1 1 1
50 2LAS8809040 LABEL BOSS 2 2 2 2
Table 18
1 1.0 Remark
11.1 Welding machines rear panels meet the plume to have good to turn on the earth
grounding, by guarantees the welder safety. When welder operation, should wear
protects the mirror, the glove, puts on protects the clothing.
11.2 When the electrical network voltage is higher than 240V/260V, the out-p ut will appear
the class, the overload, the welding machine automatically has stopped outputting and
giving the red candle demonstration warning.
11.3 Ambient temperatures high when big electric current long time continuous working, the
welding machine has stopped because of the heat outputting, gets down until the
temperature drop only then restores.
11.4 When welding machines do not use temporarily, its depository should maintain dryly,
cleanly. The environment relative humidity is not bigger than 85%.
11.5 Storing ambient temperature is -25℃~ +55℃.
11.6 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 ARC 140、160 Operating Manual
APPENDIX: ARC 140 (Sensor A) INTERCONNECT DIAGRAM
S1
16A/250V
MA1
+
_
~
~
VC2
35A/1KV
Over current red
FAN
W1
Main switch
220V/240VAC
ST2
17AM-105℃
Thermostat
Over heat green
3 1
2
RP1
1K
Welding current
Power green
+
_
~
~
VC1
35A/1KV
1
1
5
1
5
1
5
1
1
R
G
VD1
F5
VD2
F5
GND
Ig
Ig max
+24V
+12V
GND
-12V
C4
103/3KV
151
1
5
1
5
Black
red
yellow
yellow
Black
red
yellow
yellow
Black
AP1（Control PCB）
FP7.820.514-10
123
4
1XS8
1
2
3
4
5
6
1XS1
123
4
1XS2
1234567
8
1XS10
1
2
3
4
1XS9
1234567
8
1XS6
12345
1XS7
12345
6
1XS4
1
2
1XS5
1
2
3
4
5
6
1XS11
123456789
101112
1CNX
1 2 3
1J1
AP5（PWM PCB）FP7.829.004A
12345678910111213
1CNY
AP3（MOSFET PCB
）
FP7.820.016A
3TP1
3X1
1
3XP1-1
1
3XP1-2
1
5
1+1
-
1
1
Red Black
over current
PWM
1
2
3
4
5
6
7
3XP3
1
5
1
QC5
1
QC4
1
1
1
2
3
4
5
1XS3
1
3XS2-1
1
3XS2-2
1
3XS2-3
1
3XS2-4
1
3XS2-5
1
3XS2-6
1
1
1
1
1
1
AP 4（Diode PCB
）
FP7.820.017-09
1
4W2
F6x20
1
4W1
F6x20
4X1 4X2 4X3
ST1
17AM-105℃
Thermostat
4TP1 4TP2
1
1
1
2
4XS2
1
2
4XS1
1
4W3
F6x20
AP2（Power PCB）
FP7.820.002F-01
1
2XS21
1
2XS20
123
4
2XS7
123
2XS6
1
2
2XS2
1
2XS14
1
2XS15
1
2XS13
1
2XS9
1
2XS17
1
2XS16
1
2XS1112XS10
1
2XS8
1
2XS12
1
2XS19
1
2XS18
1
2
3
2XS3
1
2
2XS5
1
2
2XS4
123
2XS1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
red
+
-
4TP3
L1
1
1
1
- 29 -
BOSS ARC 140、160 Operating Manual
APPENDIX: ARC 140 (Sensor B) INTERCONNECT DIAGRAM
S1
16A/250V
MA1
+
_
~
~
VC2
35A/1KV
Over current red
FAN
W1
Main switch
220V/240VAC
ST2
17AM-85℃
Thermostat
Over heat green
3 1
2
RP1
1K
Welding current
Power green
+
_
~
~
VC1
35A/1KV
1
1
5
1
5
1
5
1
1
R
G
VD1
F5
VD2
F5
GND
Ig
Ig max
+24V
+12V
GND
-12V
C1
103/3KV
151
GND
IF
-
+
1 2
1
5
1
5
Black
red
yellow
yellow
Black
red
yellow
yellow
Black
AP 1（
Control PCB
）
FP7.820.514-10
123
4
1XS8
1
2
3
4
5
6
1XS1
123
4
1XS2
1234567
8
1XS10
1
2
3
4
1XS9
1234567
8
1XS6
12345
1XS7
12345
6
1XS4
1
2
1XS5
1
2
3
4
5
6
1XS11
123456789
101112
1CNX
1 2 3
1J1
AP5（
PWM PCB）
FP7.829.004A
12345678910111213
1CNY
AP3（
MOSFET PCB）
FP7.820.016A
3TP1
3X1
1
3XP1-1
1
3XP1-2
1
5
1+1
-
1
1
Red Black
over current
PWM
1
2
3
4
5
6
7
3XP3
1
5
1
QC5
1
QC4
1
1
1
2
3
4
5
1XS3
1
3XS2-1
1
3XS2-2
1
3XS2-3
1
3XS2-4
1
3XS2-5
1
3XS2-6
1
1
1
1
1
1
AP 4（Diode PCB
）
FP7.820.017-09
1
4W2
F6x20
1
4W1
F6x20
4X1 4X2 4X3
ST1
17AM-105℃
Thermostat
4TP1 4TP2
1
1
1
2
4XS2
1
2
4XS1
1
4W3
F6x20
AP2（
Power PCB）
FP7.820.002F-01
1
2XS21
1
2XS20
123
4
2XS7
123
2XS6
1
2
2XS2
1
2XS14
1
2XS15
1
2XS13
1
2XS9
1
2XS17
1
2XS16
1
2XS1112XS10
1
2XS8
1
2XS12
1
2XS19
1
2XS18
1
2
3
2XS3
1
2
2XS5
1
2
2XS4
123
2XS1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
red
If
+
-
4TP3
L1
1
1
1
- 30 -
BOSS ARC 140、160 Operating Manual
APPENDIX: ARC 160 (Sensor A) INTERCONNECT DIAGRAM
MA1
+
_
~
~
VC2
35A/1KV
Over current red
FAN
ST2
17AM-105℃
Thermostat
Over heat green
3 1
2
RP1
1K
Welding current
Power green
+
_
~
~
VC1
35A/1KV
1
1
5
1
5
1
5
1
1
R
G
VD1
F5
VD2
F5
GND
Ig
Ig max
+24V
+12V
GND
-12V
C3
103/3KV
151
1
5
1
5
Black
red
yellow
yellow
Black
red
yellow
yellow
AP1（
Control PCB）
FP7.820.514-10
123
4
1XS8
1
2
3
4
5
6
1XS1
123
4
1XS2
1234567
8
1XS10
1
2
3
4
1XS9
1234567
8
1XS6
12345
1XS7
12345
6
1XS4
1
2
1XS5
1
2
3
4
5
6
1XS11
1 2 3
1J1
AP5（
PWM PCB）
FP7.829.004A
12345678910111213
1CNY
AP3（
MOSFET PCB ）
FP7.820.005B
3X1
1
5
1+1
-
1
1
Red Black
over current
PWM
1
2
3
4
5
1XS3
AP4（Diode PCB
）
FP7.820.010a-11
4X1
ST1
17AM-105℃
4X2 4X3 Thermostat
1
1
1
2
4XS2
1
2
4XS1
AP2（Power PCB
）
FP7.820.002F-01
1
2XS21
1
2XS20
123
4
2XS7
123
2XS6
1
2
2XS2
1
2XS14
1
2XS15
1
2XS13
1
2XS17
1
2XS16
1
2XS1112XS10
1
2XS12
1
2XS19
1
2XS18
1
2
3
2XS3
1
2
2XS5
1
2
2XS4
123
2XS1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
+
-
L1
1
1
1
3XP1-1
1
3XP1-2
1
1
1
3XS2-1
1
3XS2-2
1
3XS2-3
1
3XS2-4
1
3XS2-5
1
3XS2-6
1
1
1
1
1
1
1
4W2
F6x20
1
4W1
F6x20
4TP1 4TP2
1
4W2
F6x20
4TP3 4TP4
1
3XS2-7
1
3XS2-8
1
1
1
2
3
4
5
6
7
3XP4
3TP1
1
5
1
3XP3-1
1
3XP3-2
S1
16A/250V
W1
Main switch
220V/240V AC
Red
Black
1
1
AP6（
Relay PCB）
FP7.820.000A
1
QC1
1
QC2
1
1
1
QC41QC3
1
QC6
1
QC5
1
1
1
2XS9
1
2XS8
1
1
123456789
101112
1CNX
1
1
1
- 31 -
BOSS ARC 140、160 Operating Manual
APPENDIX: ARC 160 (Sensor B) INTERCONNECT DIAGRAM
MA1
+
_
~
~
VC2
35A/1KV
Over current red
FAN
ST2
17AM-85℃
Thermostat
Over heat green
3 1
2
RP1
1K
Welding current
Power green
+
_
~
~
VC1
35A/1KV
1
1
5
1
5
1
5
1
1
R
G
VD1
F5
VD2
F5
GND
Ig
Ig max
+24V
+12V
GND
-12V
C1
103/3kV
151
GND
IF
-
+
1 2
1
5
1
5
Black
red
yellow
yellow
Black
red
yellow
yellow
AP1（
Control PCB）
FP7.820.514-10
123
4
1XS8
1
2
3
4
5
6
1XS1
123
4
1XS2
1234567
8
1XS10
1
2
3
4
1XS9
1234567
8
1XS6
12345
1XS7
12345
6
1XS4
1
2
1XS5
1
2
3
4
5
6
1XS11
1 2 3
1J1
AP5（
PWM PCB）
FP7.829.004A
12345678910111213
1CNY
AP3（
MOSFET PCB）
FP7.820.005B
3X1
1
5
1+1
-
1
1
Red Black
over current
PWM
1
2
3
4
5
1XS3
AP4（Diode PCB
）
FP7.820.010a-11
4X1 4X2 4X3
ST1
17AM-105℃
Thermostat
1
1
1
2
4XS2
1
2
4XS1
AP2（Power PCB
）
FP7.820.002F-01
1
2XS21
1
2XS20
123
4
2XS7
123
2XS6
1
2
2XS2
1
2XS14
1
2XS15
1
2XS13
1
2XS17
1
2XS16
1
2XS1112XS10
1
2XS12
1
2XS19
1
2XS18
1
2
3
2XS3
1
2
2XS5
1
2
2XS4
123
2XS1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
If
+
-
L1
1
1
1
3XP1-1
1
3XP1-2
1
1
1
3XS2-1
1
3XS2-2
1
3XS2-3
1
3XS2-4
1
3XS2-5
1
3XS2-6
1
1
1
1
1
1
1
4W2
F6x20
1
4W1
F6x20
4TP1 4TP2
1
4W2
F6x20
4TP3 4TP4
1
3XS2-7
1
3XS2-8
1
1
1
2
3
4
5
6
7
3XP4
3TP1
1
5
1
3XP3-1
1
3XP3-2
S1
16A/250V
W1
Main switch
220V/240V AC
Red
Black
1
1
AP6（
Relay PCB）
FP7.820.000A
1
QC1
1
QC2
1
1
1
QC41QC3
1
QC6
1
QC5
1
1
1
2XS9
1
2XS8
1
1
123456789
101112
1CNX
1
1
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