BossWeld 200X User manual

INVERTER TIG/MMA
WELDER MANUAL
Inverter Multiprocess Welder
Inverter Multiprocess Welder

2
Thank you for choosing a AC/DC 200X INVERTER AC DC TIG 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 BOSSWELD AC/DC 200X is the latest in IGBT inverter welder technology, this precise power source
delivers a smooth output in AC and DC Lift TIG, HF TIG, MMA/Stick settings, providing the user adjustments via
the full digital control. A perfect choice for the astute tradesman, or serious welding hobbyist wanting to tackle
Aluminium TIG welding.
We truly hope you enjoy using your welder!
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
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
MACHINE CARE / SAFETY INSTRUCTIONS 7
WORK AREA SAFETY 8
MAINTENANCE & DISPOSAL / GAS BOTTLE 9
FRONT & REAR PANEL LAYOUT 10
MACHINE CONTROLS PANEL 11-12
DUTY CYCLE 13
GENERAL AC/DC WELDING 14
GENERAL PULSE WELDING 15
GENERAL 2T / 4T TRIGGER CONTROL 16
GENERAL LIFT ARC / HF START 16-17
FOOT CONTROL UPGRADE OPTIONS 17
STICK / MMA WELDING SETUP 18-19
ELECTRODE / CURRENT SELECTION 20
GENERAL MMA WELDING 21
TIG WELDING SETUP 22-23
AC/DC WELD CYCLE SETUP 24-26
TUNGSTEN PREPERATION / TIG WELDING 27
TIG WELDING CONTINUED 28
26 TIG TORCH BREAKDOWN 29
TROUBLE SHOOTING 30-31

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, modications 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 - 3 Years
A warranty claim must be made within 3 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.
DO NOT GRIND YOUR PLUG
This will void any warranty on your machine

5
BOSSWELD AC/DC 200X Inverter TIG Welder Box Contents
1. AC/DC 200X Inverter TIG / MMA Welder
2. 4m 26 Series TIG Torch
3. Electrode Holder Lead
4. Welding Earth Lead
5. Gas Hose
6. Carry Strap
7. Dual Stage Argon Regulator
8. Torch Spares (not shown)
9. Owners Manual (not shown)
1
2
3
4
57
6

6
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-reecting 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 conned 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

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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 qualied / 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
inammable 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

8
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, conned 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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WARNING
Before starting any cleaning, or maintenance procedures on the welding machine, make sure that it is switched
OFF and disconnected from the mains supply.
There are no user serviceable parts inside the welder. Refer to a qualied service personnel if any internal
maintenance is required. After use, wipe the welder down with a clean soft dry cloth.
Regular inspection of the supply cord is required and if damaged is suspected, it must be immediately replaced
by the manufacturer, its service agent or similarly qualied persons in order to avoid a hazard
STORAGE/ TRANSPORT
Store the welder and accessories out of children’s reach in a dry place. If possible store the welder in the
original packaging. The appliance must unconditionally be secured against falling or rolling over during
transport.
DISPOSING OF THE PACKAGING
Recycling packaging reduces the need for landll and raw materials. Reuse of the recycled material
decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local
council authority for recycling advice.
DISPOSING OF THE WELDER
Welders that are no longer usable should not be disposed of with household waste but in an environmentally
friendly way. Please recycle where facilities exist. Check with your local council authority for recycling advice.
MAINTENANCE
DISPOSAL
GAS BOTTLE
ATTENTION! - CHECK FOR GAS LEAKS
At initial set up and at regular intervals we recommend to check for gas leakage
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the ow rate on the regulator to approximately 10-15 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on
the regulator, if the needle drops away towards zero there is a gas leak. Sometimes a gas leak can be
slow and to identify it will require leaving the gas pressure in the regulator and line for an extended time
period. In this situation it is recommended to open the cylinder valve, set the ow rate to 8-10 l/min,
close the cylinder valve and check after a minimum of 15 minutes. Ensuring adequate ventilation for
small spaces.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with
soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or ttings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your
machine. We recommend that you close the cylinder valve when the machine is not in use.
BOSSWELD, authorised representatives or agents of BOSSWELD will not be liable or responsible for
the loss of any gas.

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FRONT PANEL
1. LCD Current Meter / Display
2. Overload error indicator
3. Multi-function Control Knob
4. Positive Output Connection Socket
5. Negative Output Connection
6. Remote Controller Plug
7. Gas Output Connector
8. AC/DC Selection Switch
9. Welding Mode Selection Button
10. 2T / 4T Selection Switch
REAR PANEL
11. 240V AC Mains Power Switch
12. Gas Inlet Connector
13. Cooling Fan
14. 15 Amp Input Plug
3
4
10
9
8
2
1
5
13
6
11
7
12
14
DO NOT GRIND YOUR PLUG
This will void any warranty
on your machine

11
Multi-Function Control Knob
1. Press down to toggle through the menu.
2. Turn clockwise to increase the value
(or anti-clockwise to decrease the value)
of the selected function.
CONTROL PANEL
3
CONTROL DETAILS
15 MMA / LIFT / HF Selection Switch
16 AC / DC Selection Switch
17 2T / 4T Selection Switch
18 Parameter Selection / Adjustment control
press to change between Seconds / % / Hertz /
Amps / Volts, and scroll through weld cycle.
Turn to adjust selected parameter.
the selected parameter will be illuminated
19 LCD Display panel
20 Illuminates when Seconds is displayed
on LCD panel
21 Illuminates when Percentage is displayed
on LCD panel
22 Illuminates when Hertz is displayed on
LCD panel
23 Illuminates when Amps is displayed on
LCD panel
24 Illuminates when Volts is displayed on
LCD panel
25 Overload Indicator
26 Hot Start Indicator
27 Welding Current Indicator
28 Arc Force Indicator
22 21 20 19 26 27 28
15 16 17 23 18 24 25

12
CONTROL DETAILS - CONTINUED
The labeled gure and the corresponding table explain in detail the components of the control panel.
Where an indicator is lit on the control panel, the LCD panel will show the value
of that indicator.
123 4 7 8 10 12 13
56 9 11
1 Gas Pre-Flow Time
Seconds 0.0 – 2.0
2 Starting Current
Amps DC 10 - 170
AC 10 - 200
3 Upslope Time
Seconds 1.0 – 10.0
4 Welding Peak Current
Amps TIG DC 10 - 170
TIG AC 10 - 200
MMA DC 10 - 200
MMA AC 10 - 200
5 No Pulse Weld
On or off
6 Pulse Weld
On or off
7 Welding Base Current
Amps TIG DC 10- 170
TIG AC 10- 200
MMA DC 10- 200
MMA AC 10 – 200
8 Ratio of pulse Duration to Base Current
Duration
% 5-95
9 Pulse Frequency
Hz 0.5 – 200
10 Downslope Time
Seconds 0 - 10
11 Balance (TIG AC only)
-5- +5
12 Crater Arc Current
Seconds DC 10- 170
AC 110 – 200
13 Gas Post Flow Time
Seconds 0.1 – 10

13
DUTY CYCLE
Special note:
If this welders duty cycle is exceeded the welder will enter “thermal overload” which will
automatically stop the welding output in order to protect, both the user and the welder. You will know
the welder has gone into thermal overload when the overload error indicator light is illuminated.
The welder will then cool itself down, and once the overload error indicator light is no longer
illuminated, welding can then re-commence.
Please note. Exceeding the machine’s duty cycle, cannot be considered grounds for warranty or
return.
The term duty cycle indicates the percentage welding time available at the output current for each 10 min
period over 4 hours,
The specication plate on the machine list three given ratings at a given current and voltage.
NOTE: Amps refer to the Current setting - TIG DC setting duty cycle shown
25% 60% 100%
170 - Amps 125-Amps 100-Amps
16.8 Volts 15.6 Volts 14.4 Volts
For example this means when the machine is set at a current of 170 Amps in TIG-AC it can only weld for
Two an a half minutes in a Ten minute period. The power source is protected by a built in temperature
protection device, This will activate if the machine is operated in excess of its amperage and duty cycle
rating.
The Overload Error
Indicator light indicates
• Over temperature
• Duty cycle exceeded
BOSSWELD 200X AC/DC
692200
Duty Cycle
Amperage / Current
Voltage
DC Duty Cycle
TIG / MMA
AC MMA Duty Cycle
Amperage is
shown on digital display
AC TIG Duty Cycle

14
AC / DC WELDING
Alternating current (AC) is electricity that switches direction back and forth so the voltage also periodically
reverses because the current changes direction. Typical AC currents are what you would expect to see from
your electrical outlets in your home and often used in higher voltage devices such as household appliances.
AC current changes its polarity 120 times per second with a 60-hertz current. Reversed polarity (AC) results
in deeper penetration.
In Alternate Current (AC) welding, since the current and the magnetic eld of the arc reverse direction many
times a second, there is no net deection of the arc.
Applications of AC Welding
AC welding can be used to weld magnetic metals. This cannot be done with DC welding. AC welding is ideal
for the following types of welds:
• Downhand heavy plate
• Fast ll
• Aluminum TIG welding with high frequency
The primary advantage of using AC welding is that it allows the weld operator to weld on magnetized
materials. In AC current, the current changes direction and is not affected by magnetism. The arc remains
stable and is easier to control.
AC welding is also the preferred method for:
• TIG welding aluminum, because the current supports welding at a higher temperature.
• Making repairs on machinery because the machinery usually has a magnetized eld and is older and may
have rusty areas where there is concern about the higher heat penetration that can occur with DC welding.
• Seam welding in shipbuilding because the current settings can often be higher than those used in DC
welding and a deeper penetration of plate metals can be obtained.
The biggest drawback to using AC welding is the quality of the weld. It is not as smooth as DC welding
because of the continuous change in directional ow and there is likely to be more spatter.
Applications of DC Welding
Welding with DC is best used for:
• Hard facing
• Overhead or vertical welding
• Single carbon brazing
• Build-up of heavy deposits
• Stainless steel TIG welding
• Cutting tap
As a rule of thumb, DC is preferred for welding because:
It produces a smoother weld and there is less spatter because of the constant linear direction of the current.
It maintains a constant and stable arc and is thus is easier to handle and more reliable than AC current.
Machinery that uses DC current is generally cheaper and easier to use.
It welds thinner metals better than AC current.
Overall Strength of Welds
Overall the strength of the weld can be determined by many factors, such as:
• Proper electrode, welding apparatus and procedures;
• Properties of the materials being welded-magnetic vs. non-magnetic;
• Proper edge preparation-the cleaner the edge, the better the weld;
• Current settings – DC vs. AC;
• Speed of travel – the angle of the electrode needs to be maintained throughout the length of the joint as it is
being welded.
A strong weld can be achieved in both AC welding and DC welding so long as you weld with the current and
polarity appropriate for the material being welded. One doesn’t necessarily, always and everywhere, produce
a better weld than the other. It’s a matter of choosing the right one for your job.

15
PULSE TIG WELDING
TIG welding with the pulse feature is most often done for thin metals such as aluminum and can also be
used with copper and varieties of steel. Pulsing can be set up with a foot pedal or as a setting on your TIG
welder, but when should you use pulsing? There are some very specic applications for pulsing with a TIG
welder and then there are times when it can just come in handy to get a job done better. Here’s a look at
some TIG welding with pulse applications:
Greater Control Over the Heat
Pulse for TIG is all about improving your control when you don’t want to burn through your metal work piece.
Using the pedal or setting up the pulse will moderate the heat as you weld and ensure you have enough heat
present at the joint without laying a ton of ller metal into the joint or burning through the metal.
Too much metal in the weld joint could create a headache for your welding project, as you’ll have to stop to
grind it down and then clean up the metal before you can start welding again. The pulse setting gives you far
more control over the welding process without compromising the strength and integrity of your weld.
When You Need a Neat Weld
Pulsing your weld is an easy way to create a smooth, clean weld for a TIG welding application.
Getting yourself in a steady pulsing rhythm is an ideal way to keep moving the puddle forward or walking the
cup along a weld joint.
TIG welding is most often used when there is little margin for error and the metal is especially thin.
By pulsing along the weld joint you can moderate the amount of ller metal you add so that it’s evenly
distributed and you create a great looking weld.
Minimal Movement
If you’re in a tight spot and you don’t have a lot of room to maneuver, pulsing your TIG welder is one way to
glide along the weld joint, adding ller metal as you go, without worrying about introducing too much heat
and ller. The main thing for this application will be a steady hand on the torch and an even pace for the ller
metal. If this is a particularly tight spot, you can pick up shorter torches that have a very small head and can
t in a variety of spaces. With TIG welding you can reach a tight spot much better than with a stick welder
and you can control the input of ller metal better than with MIG, making it a great option when welding is
particularly challenging.
Moving Faster with High Speed Pulse
Given some practice, many welders can effectively weld at the high speed of 150 pulses per second,
creating neat welds in far less time. While you wouldn’t want to try a faster pulsing speed if you’re not used to
it, many welders prefer to move either really slow or really fast in order to create a steady rhythm. Pulsing at
around 20 per second has led some welders to make uneven, spotty welds.
This would be especially useful in a fabrication shop where you’re seeing a lot of the same metal work
pieces over and over and over again. If you have a handle on how fast you need to move on each piece,
then there’s a good chance you can bump up the pulsing rate to improve your welding speed.
Cycle Time
Background Time
Peak Current Level
Background
Current Level
TIME
WELD CURRENT
Peak Time

16
2T / 4T TRIGGER CONTROL
2T Trigger Control
1. Press the trigger and Hold
2. The set pre-gas ow starts and the arc starts and will upslope to the amperage
selected on the amperage dial.
3. When you want to nish the weld, release the trigger and the amperage will begin to downslope at the rate
you have selected on the downslope dial, If you selected zero the arc will stop as soon as you release the
trigger.
4T Trigger Control
1. Press the trigger and Hold
2. The set preow gas starts and the arc starts.
3. Release the trigger and the amperage will upslope to the amperage selected on the amperage dial
4. When you want to nish the weld, press and hold the trigger and the amperage will begin to downslope
at the rate you have selected on the downslope dial, amperage will remain at this level until you release
the trigger.
5. Once you have released the trigger the arc will stop and the postow gas will continue for a pre set
amount of time
LIFT ARC START
With a small movement rotate the Gas Cup
forward so that the Tungsten Electrode
touches the work piece.
Press the button on the TIG torch Now rotate the Gas Cup in the reverse
direction to lift the Tungsten electrode from the
work piece to create the arc.
3
24
Lay the outside edge of the Gas Cup on the
work piece with the Tungsten Electrode
1- 2mm from the work piece.
1

17
HF ARC START
FOOT CONTROL - OPTIONS
3 metre cord Ideal for bench work Parent-Child relationship between the welder and foot controller. This
means if you set the welder to 120 Amps, the foot controller range will be between min and 120 Amps.
Bossweld Foot Control 3mt
Part No: 660201
Lay the outside edge of the Gas
Cup on the work piece with the
Tungsten Electrode 1- 2mm from
the work piece.
1
Press the button on the TIG torch
2
The Arc will start forming an arc
between the tungsten tip and the
work piece
3
Note: Pictures may vary from your machine model

18
Plug the machine 15Amp input power lead into the
wall socket, e nsuring that the power switch on
the machine is in the OFF position.
MACHINE SET UP STICK/MMA
6.Select Stick / MMA mode
3. Connect earth Clamp
to the terminal
2. Connect Electrode holder
to the terminal
Note: The below image shows setup for DCEP / Negative Polarity
(Most Common application)
1
2
Connect earth clamp rmly to work-piece
ensuring that the clamp makes good contact
with bare metal.
Take electrode holder and twist the handle to
open the lock. Insert bare metal rod end of
electrode and twist the handle to clamp
electrode.
3
4
Assemble Arc and Earth leads into the
welding terminals depending on requirements
of electrodes. Refer to your electrode packet
for polarity and current requirements.
• DCEP/ Negative Polarity (most common application)
- Earth clamp connector into the negative terminal.
- Electrode holder connector into the positive terminal.
•DCEN/Straight Polarity
- Earth clamp connector into the Positive terminal.
- Electrode holder connector into the Negative terminal.

19
Ensure the electrode/electrode holder is not
near the work-piece or can earth out, turn the
machine on using the mains power switch.
The front displays will light up and the cooling
fan will start.
Select Stick / MMA on Welding Output Mode
Switch.
Select the desired welding wave form (AC or
DC) using the AC/DC Selection switch
(DC is the most common electrode type)
3. Connect earth Clamp
to the terminal
MACHINE SET UP STICK/MMA - CONTINUED
5
6
7
Select your required amperage by
turning the Multi-Function Control knob
You can adjust the Hot Start by pressing the
Multi-Function Control knob to cycle to Hot start
then adjusting to the required parameter
You can adjust the Arc force by pressing the
Multi-Function Control knob to cycle to Arc
Force then adjusting to the required
parameter.
8
9
10

20
Amperage Selection Guide
Rod Size/ Gauge Welding Current
1.6mm 40-50 Amps
2.0mm 50-75 Amps
2.5mm 75-105 Amps
3.2mm 105-140 Amps
4.0mm 140-160 Amps
WELDING CURRENT
Welding current level is determined by the size of electrode - the normal operating range and current are
recommended by manufacturers. Typical operating ranges for a selection of electrode sizes are illustrated in
the table. As a rule of thumb when selecting a suitable current level, an electrode will require about 40 Amps
per millimetre (diameter). Therefore, the preferred current level for a 4mm diameter electrode would be 160
Amps, but the acceptable operating range is 140 to 180 Amps. It is important to match the machine to the job
Average Metal Thickness Electrode Size
1.0 - 2.0mm 2.0mm
2.0 - 5.0mm 2.6mm
5.0 - 8mm 3.2mm
8.0mm + 4.0mm
ELECTRODE SIZE SELECTION
Electrode size selection will be determined by the thickness of the section being welded. A thicker section will
need a larger diameter electrode. The table below shows the maximum size of electrodes for average
thicknesses of section (based on General Purpose 6013 Electrode).