BossWeld POWERPULSE 250 Manuale utente
DUAL PULSE
SYNERGIC MST
INVERTER WELDER
MANUAL
POWERPULSE 250
2
YEAR
LIMITED
WARRANTY
2
Thank you for choosing a BOSSWELD POWERPULSE 250PFC Inverter MST Welder
In this manual you will nd instructions on how to set up your welder along with general welding information,
safety information and helpful tips. We encourage you to go online to our website for more tips and
troubleshooting as well as many welding resources.
The POWERPULSE 250 is a new inverter-based MIG/MMA/TIG Welding machine with Synergic Programs and
Dual pulse functions. The MIG function allows you to weld with Gas Shielded wire applications giving excellent,
professional welding results. Easy step-less adjustment of voltage and wire feed coupled with integrated digital
meters allows easy setting of welding parameters. The POWERPULSE 250 features MIG welding with
Synergic welding programs designed for ease of use with your selected gas mixture. The operator selects the
gas mixture and wire diameter they are using then simply start welding. Once this is done the operator can
make ne adjustments to the voltage for even greater control of the weld pool. The added Lift-Arc DC TIG
capability delivers perfect arc ignition every time and a remarkably smooth stable arc produces high quality
TIG welds. TIG functionality includes adjustable Down Slope & Post Gas as well as being gas solenoid-valve
equipped. The stick welding (MMA) capability delivers easy electrode welding with high quality results, includ-
ing cast Iron, stainless and low hydrogen. An additional feature is the Spool gun ready function that allows the
simple connection of Spool Gun for the use of thin or softer wires that don’t have the column strength to feed
through MIG torches, such as aluminum wire. In the JOB mode, 100 different JOB records can be stored and
called , improve the quality of welding process .
Arc welding with the POWERPULSE 250 machine t is suitable for all positions welding for various plates made
of stainless steel, carbon steel, alloyed steel etc. Applications applied to pipe installment, petrochemical,
architecture equipment, car repair, bicycle repair, handicraft and common steel fabrication.
The POWERPULSE 250 machines has built-in automatic protection functions to protect the machines from
over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm lamp on the
front panel will light up and output current will be shut off automatically for the machine to protect itself and
prolong the equipments life!
Every effort has been made to ensure that this manual has been prepared accurately, however errors and omissions are excepted.
BOSSWELD is a trademark of Dynaweld Industrial Supplies Pty Ltd.
MMIG
• Simple to learn
• MIG Wire is fed through the gun to create the weld pool
• Gas or flux prevents oxidisation in the weld
• Weld with or without gas
• Point and pull the trigger
• Great for maintenance, small projects
& automotive repairs
METAL TYPES
Mild steel, stainless steel & aluminium
SSTICK
• Easiest process to learn
• Best choice for quick repairs
• Slower than MIG welding
• Forgiving in dirty/rusty environments
• Not recommended for thin sheet metal welding
METAL TYPES
Mild steel, stainless steel & cast iron
TTIG
• Gives a better weld finish
• Accurate heat control
• Considered the most challenging process to learn
• Good way to weld thin material
• Argon gas is required
METAL TYPES
Mild steel, stainless steel & aluminium
PPLASMA CUTTING P
• Wide range of uses to cut conductive metals
• Uses an accelerated jet of hot plasma
• High speed/low cost cutting method
• Used extensively replacing gas cutting methods
• Air compressor is required
METAL TYPES
Mild steel, stainless steel & aluminium
3
CONTENTS PAGE
WARRANTY 4
BOX CONTENTS 5
WARNINGS 6-8
MACHINE CARE / SAFETY INSTRUCTIONS 9
WORK AREA SAFETY 10
MAINTENANCE & DISPOSAL / GAS BOTTLE 11
FRONT & REAR PANEL LAYOUT 12
MACHINE INSIDE 13
MACHINE CONTROLS PANEL 14-18
DUAL PULSE FUNCTION 19
WIRE SPOOL & WIRE FEED SET UP 14
MIG TORCH SETUP 15
LINER INSTALLATION / REPLACEMENT 16
DRIVE ROLLER SIZE 25
2T / 4T TRIGGER CONTROL INFORMATION 17
WAVE CONTROL 17
MIG TORCH AND CONSUMABLE CARE 18
STICK / MMA WELDING SETUP 19-20
GENERAL MMA WELDING 21
GASLESS MIG WELDING SETUP 22-24
GAS MIG WELDING SETUP 24-27
GENERAL MIG WELDING 28-31
TIG WELDING SETUP 32-33
LIFT ARC TIG 34
TUNGSTEN PREPARATION 35
GENERAL TIG WELDING 36
BZ24 MIG TORCH PARTS BREAK DOWN 37
26 TIG TORCH BREAKDOWN 38
HELPFUL INFORMATION & TROUBLE SHOOTING 39-42
4
WARRANTY
This warranty is in addition to the statutory warranty provided under Australian Consumer Law, but does not
include damage resulting from transport, misuse, neglect or if the product has been tampered with.
The product must be maintained as per this manual, and installed and used according to these instructions on
an appropriate power supply. The product must be used in accordance with industry standards and acceptable
practice.
This warranty covers the materials used to manufacture the machine and the workmanship used to produce the
item. This Warranty does not cover damage caused by:
1. Normal wear and tear due to usage
2. Misuse /abuse or Neglect of the item
3. Transport / handling breakages
4. Lack of maintenance, care and cleaning
5. Environmental factors, such as usage in temperatures exceeding 40 degrees, above 1000mt sea level, rain,
water, excessive damp, cold or humid conditions.
6. Improper setup or installation
7. Use on Incorrect voltage or non authorised electrical connections and plugs
8. Use of non standard parts
9. Repair, case opening, tampering with, modications to any part of the item by non authorised BOSSWELD
repairers.
This warranty covers the machine only and does not include Torches, Leads, Earth Clamps, Electrode holders,
Plasma Torches, Tig Torches and any of the parts on those items unless there is a manufacturing fault.
1. REGISTRATION
Purchasers are encouraged to register for warranty on our website. www.bossweld.com.au/warranty
2. TIME PERIOD - 2 Years
A warranty claim must be made within 2 years from the date of purchase of this product. Any claim must include
proof of purchase.
3. HOW TO MAKE A CLAIM - NEED SOME HELP?
• Visit our website www.bossweld.com.au/troubleshooting for many helpful tips and guides to assist with the
setup and usage of your new machine. Still stuck….?
• Call the BOSSWELD Helpdesk on 1300 460 665 for over the phone assistance.
• If the machine is not operational then return the item to the place of purchase.
BOSSWELD MAKES NO 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 PARTICULAR PURPOSE.
2
YEAR
LIMITED
WARRANTY
DO NOT GRIND YOUR PLUG
This will void any warranty on your machine
5
BOSSWELD POWERPULSE 250PFC Inverter MIG/MMA Welder Box Contents
1. BOSSWELD POWERPULSE 250PFC Inverter DC MIG Welder
2. 3 metre 36 Series MIG Torch
3. Welding cable with electrode holder
4. Earth cable with earth clamp
5. Gas Hose
6. Dual Stage Argon Regulator
7. Torch Spares
8. Carry Strap
9. Drive Roller (spare – not shown)
10. Operating Manual (not shown)
1
5
6
78
32 4
6
ELECTRIC SHOCK CAN KILL.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on. The input power circuit and internal machine
circuits are also live when power is on. In Mig/Mag welding, the wire, drive rollers, wire feed
housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed
or improperly grounded equipment is dangerous.
• Never touch live electrical parts.
• Wear dry, hole-free gloves and clothes to insulate your body.
• Be sure to install the equipment correctly and ground the work or metal to be welded to a
good electrical (earth) ground according to the operation manual.
• The electrode and work (or ground) circuits are electrically “hot” when the machine is ON.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves
to insulate hands.
• In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.
• Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
• Be Careful when using the equipment in small places, falling-off and wet circumstance.
• Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
• Maintain the electrode holder, work clamp, welding cable and welding machine in good,
safe operating condition. Replace damaged insulation.
• Never dip the electrode in water for cooling.
• Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of both
welders.
• When working above the oor level, use a safety belt to protect yourself from a fall should
you get an electric shock!
ARC RAYS: Harmful to people’s eyes and skin.
Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared
rays that can burn eyes and skin.
• Use a shield with the proper lter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding.
• Use suitable clothing made from durable ame-resistant material to protect your skin and that
of your coworkers from the arc rays.
• Protect other nearby personnel with suitable, non-ammable screening and /or warn them not
to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
SELF-PROTECTION
• Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
• Do not put your hands near the engine fan. Do not attempt to override the governor or idler
by pushing on the throttle control rods while the engine is running.
WELDING SPARKS can cause re or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode.
Flying sparks from the welding arc, hot work piece, and hot equipment can cause res and
burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or re. Check and be sure the area is safe before doing any welding
• Remove re hazards material from the welding area. If this is not possible, cover them to
prevent the welding sparks from starting a re. Remember that welding sparks and hot
materials from welding can easily go through small cracks and openings to adjacent areas.
Avoid welding near hydraulic lines. Have a re extinguisher readily available.
• Where compressed gases are to be used at the job site, special precautions should be used
to prevent hazardous situation.
• When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a re hazard.
• Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to
insure that such procedures will not cause ammable or toxic vapors from substances inside.
They can cause an explosion even though they have been “cleaned”.
• Vent hollow castings or containers before heating, cutting or welding. They may explode.
7
Gas Cylinders and Gas Build up
• Use only compressed gas cylinders containing the correct shielding gas for the process used
and properly operating regulators designed for the gas and pressure used. All hoses, ttings,
etc. should be suitable for the application and maintained in good condition.
• Always keep cylinders in an upright position securely chained to an undercarriage or xed
support.
• Cylinders should be located:
- Away from areas where they may be struck or subjected to physical damage.
- At a safe distance from arc welding or cutting operations and any other source of heat,
sparks, or ame.
• Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a gas
cylinder.
• Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
• Valve protection caps should always be in place and hand tight except when the cylinder is in
use or connected for use.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
Because gas cylinders are normally part of the welding process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open
ames sparks, and arcs.
• Insure cylinders are held secure and upright to prevent tipping or falling over.
• Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape
welding cables over the cylinder.
• Never weld on a pressurised gas cylinder, it will explode and kill you.
• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas
regulator.
The build up of gas can causes a toxic environment, deplete the oxygen content in the air
resulting in death or injury. Many gases used in welding are invisible and odorless.
• Shut off shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electric and Magnetic Fields.
Electric current owing through any conductor causes localized Electric and Magnetic Fields
(EMF). The discussion on the effect of EMF is ongoing in the entire world. Up to now, no mate-
rial evidences show that EMF may have effects on health. However, the research on the effect
of EMF is still ongoing. Before any conclusion, we should minimize exposure to EMF as few as
possible.
In order to minimize EMF, we should use the following procedures:
• Route the electrode and work cables together – Secure them with tape when possible.
• All cables should be put away and far from the operator.
• Never coil the power cable around your body.
• Make sure welding machine and power cable to be far away from the operator as far as
possible according to the actual circumstance.
• Connect the work cable to the workpiece as close as possible to the area being welded.
• The people with heart-pacemaker should be away from the welding area.
• Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair. Wear
earplugs when welding out of position or in conned places. Always wear safety glasses with
side shields when in a welding area.
• Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase
the possibility of the welding current passing through lifting chains, crane cables or other
alternate circuits. This can create re hazards or overheat lifting chains or cables until they
fail
8
The device and packaging material are not toys! Children must not be allowed to play with the machine and its
accessories. Plastic parts and packaging are choking risks for children.
• Open the packaging and remove the welder carefully.
• Check that the delivery is complete.
• If possible, store the packaging until the warranty period has expired.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
GLOVES AND PROTECTIVE CLOTHING
Use protective gloves and re resistant protective clothing when welding.
Avoid exposing skin to ultraviolet rays produced by the arc.
WELDING HELMET
Under no circumstances should the welder be operated unless the operator is wearing a
welding helmet to protect the eyes and face. There is serious risk of eye damage if a helmet is
not used. The sparks and metal projectiles can cause serious damage to the eyes and face.
The light radiation produced by the arc can cause damage to eyesight, and burns to skin.
Never remove the welding helmet whilst welding.
SAFETY GLASSES
After welding use appropriate safety glasses when brushing, chipping or grinding the slag from
the weld.
OTHER PERSONS
Ensure that other persons are screened from the welding arc and are at least 15 metres away
from the work piece. Always ensure that the welding arc is screened from onlookers, or people
just passing by. Use screens if necessary, or non-reecting welding curtain. Do not let children
or animals have access to the welding equipment or to the work area.
SWITCHING OFF
When the operator has nished welding they must switch the welder off.
DO NOT put the electrode holder down with the welder switched ON.
When leaving the welder unattended, move the ON/OFF switch to the OFF position and
disconnect the welder from the electrical mains supply.
Do not leave hot material unattended after welding.
FUMES &GASES ARE DANGEROUS
Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding
produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of
the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding
fumes and gases.
• In conned or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
• Do not weld in locations near de-greasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can
give off toxic fumes when welded. Do not weld these materials unless the area is very well
ventilated, and or wearing an air supplied respirator.
WARNING
9
Keep the welding cables, earth clamp and electrode holder in good condition. Failure to do this can result in
poor welding quality, which could be dangerous in structural situations.
Prior to use, check for breakage of parts and any other conditions that may affect operation of the welder.
Any part of the welder that is damaged should be carefully checked to determine whether it will perform its
intended function whilst being safe for the operator. Any part that is damaged should be properly repaired, or
replaced by an authorised service centre.
IMPROPER USE
It is hazardous to use the welding machine for any work other than that for which it was designed e.g. do not
use welder for thawing pipes.
HANDLING
Ensure the handle is correctly tted. As welding machines can be heavy, always use safe lifting practices when
lifting.
POSITION AND HANDLING
To reduce risk of the machine being unstable / danger of overturning, position the welding machine on a
horizontal surface that is able to support the machine weight. Operators MUST NOT BE ALLOWED to weld in
raised positions unless safety platforms are used.
WARNING
The user of this welder is responsible for their own safety and the safety of others. It is important to read,
understand and respect the contents of this user guide. When using this welder, basic safety precautions,
including those in the following sections must be followed to reduce the risk of re, electric shock and personal
injury. Ensure that you have read and understood all of these instructions before using this welder.
Persons who are not familiar with this user guide should not use this welder. Keep this booklet in a safe place
for future reference.
TRAINING
The operator should be properly trained to use the welding machine safely and should be informed about the
risks relating to arc welding procedures. This user guide does not attempt to cover welding technique. Training
should be sought from qualied / experienced personnel on this aspect, especially for any welds requiring a high
level of integrity for safety.
SERIOUS FIRE RISK
The welding process produces sparks, droplets of fused metal, metal projectiles and fumes.
This constitutes a serious re risk. Ensure that the area in which welding will be undertaken is clear of all
inammable materials. It is also advisable to have a re extinguisher, and a welding blanket on hand to protect
work surfaces.
MACHINE CARE / SAFETY
SAFETY INSTRUCTIONS
10
Ensure a clear, well lit work area with unrestricted movement for the operator.
The work area should be well ventilated, as welding emits fumes which can be dangerous.
Always maintain easy access to the ON/OFF switch of the welder, and the electrical mains supply.
Do not expose the welder to rain and do not operate in damp or wet locations
WORK AREA
Where welding must be undertaken in environments with increased risk of electric shock, conned spaces or in
the presence of ammable or explosive materials, it is important that the environment be evaluated in advance
by an “expert supervisor”. It is also recommended that welding in these circumstances be carried out in the
presence of persons trained to intervene in emergencies.
AVOID ELECTRICAL CONTACT
Use adequate electrical insulation with regard to the electrode, the work piece and any accessible earthed metal
parts in the vicinity. Avoid direct contact with the welding circuit. The no load voltage between the earth clamp
and the electrode can be dangerous under certain circumstances.
Note: For additional protection from electric shock. It is recommended that this welder be used in conjunction
with a residual current device (RCD) with rated residual current of 30MA or less.
In general the use of extension leads should be avoided. If used however, ensure that the extension lead is
used with the welder is of a suitable current rating and heavy duty in nature that MUST have an earth
connection. If using the welder outdoors, ensure that the extension lead is suitable for outdoor use. Always keep
extension leads away from the welding zone, moisture and any hot materials.
WELDING SURFACES
Do not weld containers or pipes that hold, or have held, ammable liquids or combustible gases or pressure.
Do not weld on coated, painted or varnished surfaces as the coatings may ignite, or can give off dangerous
fumes.
WORK PIECE
When welding, the work piece will remain at high temperature for a relatively long period. The operator must not
touch the weld or the work piece unless wearing welding gloves. Always use pliers or tongs. Never touch the
welded material with bare hands until it has completely cooled.
VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES
Working with more than one welding machine on a single work piece, or on work pieces that are connected,
may generate a dangerous accumulation of no-load voltage between two different electrode holders or torches,
the value of which may reach double the allowed limit.
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