Linde BOC RAPTOR 135 User manual

135 MIG (gasless)
Operating Manual
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Welcome to a better way of welding
Congratulations on puchasing the Raptor 135 MIG (gasless) weldingmachine.
The products in BOC's range perform with reliability and have the backing of one of
South Pacic's leading welding suppliers.
This operating manual provides the basic knowledge required for MIG welding, aswell
as highlighting important areas of how to operate the Raptor machine.
With normal use, and by following these recommended steps, your Raptor machine
can provide you with years of trouble-free service.
Raptor equipment and technical support is available through the national
BOCCustomer Engagement Centre or contact your local Gas & Gear outlet.
Important Notice: This document has been prepared by BOC
Limited ABN 95 000 029 729 ('BOC'), as general information and
does not contain and is not to be taken as containing any specic
instructions. Thedocument has been prepared in good faith and is
professional opinion only. Information in this document has been
derived from third parties, and though BOC believes it to be reliable
as at the time of printing, BOC makes no representation or warranty
as to the accuracy, reliability or completeness of information in this
document and does not assume any responsibility for updating any
information or correcting any error or omission which may become
apparent after the document has been issued. Neither BOC nor
any of its agents has independently veried the accuracy of the
information contained in this document. The information in this
document is commercial in condence and is not to be reproduced.
The recipient acknowledges and agrees that it must make its own
independent investigation and should consider seeking appropriate
professional recommendation in reviewing and evaluating
the information. This document does not take into account the
particular circumstances of the recipient and the recipient should
not rely on this document in making any decisions, including but not
limited to business, safety or other operations decisions.
Except insofar as liability under any statute cannot be excluded,
BOC and its a󹟾liates, directors, employees, contractors and
consultants do not accept any liability (whether arising in contract,
tort or otherwise) for any error or omission in this document
or for any resulting loss or damage (whether direct, indirect,
consequential or otherwise) su󹟽ered by the recipient of this
document or any other person relying on the information contained
herein. The recipient agrees that it shall not seek to sue or hold
BOC or their respective agents liable in any such respect for the
provision of this document or any other information.

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Welcome to a better way of welding 2
1.0 Recommended Safety Guidelines 4
2.0 Recommended Safety Precautions 5
2.1 Health Hazard Information 5
2.2 Personal Protection 5
2.3 Electrical Shock 6
2.4 User Responsibility 6
Switch on to electrical safety 7
3.0 Installation 10
3.1 How to set up your machine for self-shielded
ux-cored welding 10
3.2 How to install Shoulder Strap 11
4.0 Operation 12
4.1 Control Panel 12
4.2 Back Panel 12
4.3 Operating instructions 12
5.0 Machine Specifications 13
6.0 Basic Welding Techniques 14
6.1 Fundamentals of Gasless Flux Cored
ArcWelding 14
7.0 Periodic Maintenance 15
7.1 Power Source 15
7.2 Torch 15
8.0 Trouble Shooting 16
9.0 Warranty Information 17
9.1 Terms of Warranty 17
9.2 Limitations on Warranty 17
Contents

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• Repair or replace defective cables immediately.
• Never watch the arc except through
lenses of the correct shade.
• In conned spaces, adequate ventilation and
constant observation are essential.
• Leads and cables should be kept clear
of passageways.
• Keep re extinguishing equipment at a handy
location in the shop.
• Keep primary terminals and live parts e󹟽ectively
covered.
• Never strike an electrode on any gas cylinder.
• Never use oxygen for venting containers.
1.0 Recommended Safety Guidelines
Diagram and safety explanation
Electrical safety alert
Welding electrode causing
electric shock
Fumes and gases coming from
welding process
Welding arc rays
Read instruction manual
Become trained
Diagram and safety explanation
Wear dry, insulated gloves
Insulate yourself from
work and ground
Disconnect input power before
working on equipment
Keep head out of fumes
Use forced ventilation or local
exhaust to remove fumes
Use welding helmet with
correct shade of lter
Some safety precautions BOC recommends are as follows:

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2.1 Health Hazard Information
The actual process of welding is one that
can cause a variety of hazards. All appropriate
safety equipment should be worn at all times, i.e.
headwear, respiratory, hand and body protection.
Electrical equipment should be used in accordance
with the manufacturer’s recommendations.
Eyes
The process produces ultra violet rays that can
injure and cause permanent damage. Fumes can
cause irritation.
Skin
Arc rays are dangerous to uncoveredskin.
Inhalation
Welding fumes and gases are dangerous to the
health of the operator and to those in close
proximity. The aggravation of pre-existing
respiratory or allergic conditions may occur in some
workers. Excessive exposure may cause conditions
such as nausea, dizziness, dryness and irritation of
eyes, nose andthroat.
2.2 Personal Protection
Respiratory
Conned space welding should be carried out
with the aid of a fume respirator or air supplied
respirator as per AS/NZS 1715 and AS/NZS 1716
Standards.
• You must always have enough ventilation in
conned spaces. Be alert to this at all times.
• Keep your head out of the fumes rising from
thearc.
• Fumes from the welding of some metals could
have an adverse e󹟽ect on your health. Don’t
breathe them in. If you are welding on material
such as stainless steel, nickel, nickel alloys
or galvanised steel, further precautions are
necessary.
• Wear a respirator when natural or forced
ventilation is not good enough.
Eye protection
A welding helmet with the appropriate welding
lter lens for the operation must be worn at all
times in the work environment. The welding arc
and the reecting arc ash gives out ultraviolet
and infrared rays. Protective welding screen and
goggles should be provided for others working in
the same area.
Recommended filter shades for arc welding
Less than 150 amps Shade 10*
150 to 250 amps Shade 11*
250 to 300 amps Shade 12
300 to 350 amps Shade 13
Over 350 amps Shade 14
*Use one shade darker for aluminium
Clothing
Suitable clothing must be worn to prevent
excessive exposure to UV radiation and sparks. An
adjustable helmet, ameproof loose tting cotton
clothing buttoned to the neck, protective leather
gloves, spats, apron and steel capped safety boots
are highly recommended.
2.0 Recommended Safety Precautions