Boss TIG 160HF, TIG 200HF Operating Manual
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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BOSS TIG 160HF、200HF 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--------------------------------------------------------------------------------------------10
2.03 Duty cycle-------------------------------------------------------------------------------------------------10
3.0 OPERATOR CONTROLS-------------------------------------------------------------------------------11
3.01 TIG HF Series controls--------------------------------------------------------------------------------11
3.02 Weld parameter description--------------------------------------------------------------------------13
3.03 Weld parameters for TIG HF series----------------------------------------------------------------13
4.0 SET-UP FOR MMA (STICK) AND GTAW (TIG)----------------------------------------------------14
4.01 Stick w elding---------------------------------------------------------------------------------------------15
4.02 DC TIG welding-----------------------------------------------------------------------------------------15
4.03 DC pulse TIG welding---------------------------------------------------------------------------------15
5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------16
6.0 BASIC TIG WELDING GUIDE--------------------------------------------------------------------------17
6.01 Electrode Polarity---------------------------------------------------------------------------------------17
6.02 Tungsten Electrode Current Ranges---------------------------------------------------------------17
6.03 Tungsten Electrode Types----------------------------------------------------------------------------17
6.04 Guide for Selecting Filler Wire Diameter----------------------------------------------------------17
6.05 Shielding gas selection--------------------------------------------------------------------------------18
6.06 TIG w elding parameters for low carbon & low alloy steel pipe-------------------------------18
6.07 Welding parameters for steel------------------------------------------------------------------------18
7.0 BASIC ARC WELDING GUIDE------------------------------------------------------------------------19
7.01 Electrode polarity---------------------------------------------------------------------------------------19
7.02 Effects of stick w elding various materials---------------------------------------------------------19
8.0 MAINTENANCE--------------------------------------------------------------------------------------------20
9.0 BASIC TROUBLESHOOTING-------------------------------------------------------------------------20
9.01 Check the item and excrescent phenomenon exclusion method---------------------------20
9.02 TIG w elding problems---------------------------------------------------------------------------------22
9.03 Stick w elding problems--------------------------------------------------------------------------------23
9.04 Power source problems-------------------------------------------------------------------------------24
10.0 PARTS LIST-------------------------------------------------------------------------------------------------25
11.0 REMARK-----------------------------------------------------------------------------------------------------30
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BOSS TIG 160HF、200HF 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 TIG 160HF、200HF 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 TIG 160HF、200HF 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 TIG 160HF、200HF 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 TIG 160HF、200HF 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 TIG 160HF、200HF Operating Manual
2.0 INSTALLATION RECOMMENDATION
Installation Environment
TIG HF 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:
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
TIG 160HF Minimum 4mm2
220V/22A
240V/20.2A
220V/24.5A
240V/22.5A
160A/16.4V@60%
125A/15V@100%
140A/25.6V@60%
125A/25V@100%
TIG 200HF Minimum 6mm2
220V/32A
240V/29.3A
220V/33.5A
240/30.7A
200A/18V@60%
160A/16.4V@100%
160A/26.4V@60%
140A/25.6V@100%
Table 1 Primary current circuit sizes to achieve maximum current
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BOSS TIG 160HF、200HF 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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BOSS TIG 160HF、200HF Operating Manual
Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT
SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. The welding machine
will turn on after the input capacitors have charged to full operating voltage (after approximately 1.5 seconds) .
Introduction
The importance of correct installation of high frequency welding equipment cannot be overemphasized.
Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation.
The following information is intended as a guide for personnel installing high frequency welding machine.
W arning
Explosives
The high frequency section of this machine has an output similar to a radio transmitter. The machine
should NOT be used in the vicinity of blasting operations due to the danger of premature firing.
Computers
It is also possible that operation close to computer installations may cause computer malfunction.
High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the
following ways:
Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur
through apertures such as open access panels. The shielding of the high frequency unit in the
Power Source will prevent direct radiation if the equipment is properly grounded.
Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the
installation (mains) by direct coupling. The energy is then transmitted by both radiation and
conduction. Adequate shielding and filtering is provided in the Power Source.
Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads,
diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of
interference. Looping and suspending of leads should be avoided where possible.
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.
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