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  1. #1
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    Default Bossweld PowerPro 250 issues

    Never used anything but AC stick (and OxyAcetylene back in my teens).

    I'm about to try some MIG (MAG) with one of these:
    99a410_6276c2c69f194627aabd0367d52fdf91~mv2_d_3816_3276_s_4_2.jpg
    15A power lead, still got the cover film over the displays, probably barely used (i.e. might be on the first reel).



    Owner has demonstrated that it welds, but a few little issues have thrown me:




    Issue 0: I can't find a manual online for this old model.
    Have asked the few distributors that still list that model, but am not hopeful


    Issue 1: It trips a 32A RCBO when switched on. Resetting the breaker gets past this, but it is odd.
    Haven't tried megger/earth leakage test yet. Afraid of damaging electronics.


    Issue 2: The spool ON/OFF switch is reversed? Off position does continuous feeding.


    Issue 3: One previous user complained that the tip was missing a ceramic or something.
    As far as I know, only TIG uses a ceramic shield?
    Only thing I can see is this nozzle style has no "shield insulator"?
    ...which means if you touch the shield to the job, it will arc/stick.



    Hoping our excellent forum's combined wisdom can help me out

  2. #2
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    Default

    Issue 3- That looks like a binzel 24 or 36 style gun. Which do in fact use a ceramic diffuser. If there is any spatter between the nozzle friction fit surface and the inner contact tip adapter area- yeah, it will arc out- the nozzle is not internally insulated like some other styles.

    Issue 1 - As for RCBO - it's not a promising symptom.
    issue 2 - Spool function may or may not be a bigger problem (control board), which if you can't get the manual (issue 0), you've probably got buckley's of getting that part...

  3. #3
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    Default

    Quote Originally Posted by Commander_Keen View Post
    Issue 3- That looks like a binzel 24 or 36 style gun. Which do in fact use a ceramic diffuser. If there is any spatter between the nozzle friction fit surface and the inner contact tip adapter area- yeah, it will arc out- the nozzle is not internally insulated like some other styles.

    Issue 1 - As for RCBO - it's not a promising symptom.
    issue 2 - Spool function may or may not be a bigger problem (control board), which if you can't get the manual (issue 0), you've probably got buckley's of getting that part...
    Issue 3 is a non issue as any mig nozzle will become live if spatter builds up, even the Bernard guns which have an insulator in the nozzle (only goes part way inside the nozzle) will arc out the nozzle if spatter builds up. Binzel is one of THE big names in MIG guns.
    Issue 2 is likely a switch reversed if is just a toggle switch. Provided the wire feeder works correctly in it's other functions, I wouldn't be too concerned.
    Issue 1 could be a problem, but not necessarily a major one given that it is not a constant condition.
    For a manual, I would suggest you contact https://dynaweld.com.au/bossweld-welding-equipment/

  4. #4
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    Default

    Quote Originally Posted by Karl Robbers View Post
    Issue 3 is a non issue as any mig nozzle will become live if spatter builds up, even the Bernard guns which have an insulator in the nozzle (only goes part way inside the nozzle) will arc out the nozzle if spatter builds up. Binzel is one of THE big names in MIG guns.
    I'd argue / state that if it gets that bad after a few rolls of wire on a new machine, the guy using it was probably a numpty.
    Any welder worth his salt wouldn't let the spatter get to that point.

    I've worked with non-skilled production work guys doing menial tasks at big plants who even get it, nad clean the spatter, use a dip etc. Still can't stop them using the torch as a hammer though...

    On bernard, that is the single most overcomplicated torch setup around. the center-fire tips are held in by the stumpy nozzle's inbuilt gas screen- so all sorts of schmutz gets stuck up there.
    Kemppi is good for a nozzle insulator, so is tweco 4 and 5. There is a reason why most torches are Binzel or Binzel copies.

  5. #5
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    Quote Originally Posted by Commander_Keen View Post
    On bernard, that is the single most overcomplicated torch setup around. the center-fire tips are held in by the stumpy nozzle's inbuilt gas screen- so all sorts of schmutz gets stuck up there.
    Kemppi is good for a nozzle insulator, so is tweco 4 and 5. There is a reason why most torches are Binzel or Binzel copies.
    I'd certainly agree that Bernard has been elevated to a place way above their rightful status.
    On the subject of Tweco No.4 guns, mileage varies. I love the heavy duty style nozzles (Tweco 5 style with screw on ends) but cannot understand why they ever decided to inflict the swaged push on No.2 style upon users of a medium to heavy duty mig gun.

  6. #6
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    Default

    Yeah not a fan either. Particularly how it rattles around, and if you bump it, the contact tip stickout can be changed for the worse.
    I run a current model Binzel 24 on my small single phase machine- a good balance between being nimble to use, with a good torch duty and cheap plentiful parts.

  7. #7
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    OK. There wasn't much spatter inside the nozzle:
    IMG_2113.jpg
    and checking with a multimeter revealed open circuit between the tip and the neck+sleeve.
    (I had assumed they were one piece of brass, and couldn't work out how a ceramic insulator would work)



    I did a few sample welds to get my hand/eye/brain adjusted for MIG:
    IMG_2118.jpg


    Was going fine, until I tried to plug a small hole in 3mm plate. Somehow blew out one side, and then got a big blob stuck on the end of the tip when trying to build up my mistake. Ground that off, and I could pull the wire through, but welding got weird after that.



    Took the tip off, found a tiny drill to clean it out, then noticed it was a 1.0mm. Wire is a bit loose in that, so, off to local Bunnings to see what they have. Pack of ten 0.9mm is $6.95:
    e030133f-9228-467d-ba89-a4a2229efc84.jpeg
    Came back with them, then thought to check the wire gauge. Machine has 0.8mm
    Back to Bunnings to swap, but they only have this "heavy duty" style:
    d8b0071e-1cc9-4c2d-bf90-acd3c3bb84f8.jpeg
    Then I remembered CommanderKeen saying it was a Binzel 24 style. Bunnings has an accessory set which has a little ceramic thingy! Took it back, fitted the ceramic diffuser:
    c32ba4fc-f12b-4fad-b47a-2ce649316e99.jpeg IMG_2115.jpg
    checked tip sizes and realised that pack only has 1.2mm & 0.9mm. Oh well, use the slim 0.9, will order some 0.8mm later.


    Welding is still weird. Machine owner comes and fiddles, finds feed is way too slow, eventually works out wire has slipped off one roller? Gets it back working, I start tacking, puddling, and generally having a good day:
    IMG_2128.jpg

    ...except for the sunburn inside my bicep that I noticed the next day:
    IMG_2130.jpg

  8. #8
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    On the subject of the ceramic gas diffuser in Binzel mig guns. If it is cracked or badly damaged and you have no replacement, you are better to remove it totally than to try and continue welding as it can cause gas turbulence issues. The same applies to Bernard nozzles where the internal insulation is worn and furry, except that replacement is your only option there.

  9. #9
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    Karl, funny you should say that. This is the diffuser after 3 weeks:

    IMG_2224.jpg

    (I think a few other people have been using it as a hammer )



    You're saying remove it completely, until I can find a cheap 5 pack of new ones?

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