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

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2.3 Electrical Shock
• Never touch ‘live’ electrical parts.
• Always repair or replace worn or damagedparts.
• Disconnect power source before performingany
maintenance or service.
• Earth all work materials.
• Never work in moist or damp areas.
Avoid electric shock by
• Wearing dry insulated boots
• Wearing dry leather gloves
• Never change electrodes with bare
handsorwetgloves
• Never cooling electrode holders in water
• Work on a dry insulated oor where possible
• Never hold the electrode and holder under
yourarm.
2.4 User Responsibility
• Read the Operating Manual prior to installation
of this machine.
• Unauthorised repairs to this equipment may
endanger the technician and operator and will
void your warranty. Only qualied personnel
approved by BOC should perform repairs.
• Always disconnect mains power before
investigating equipment malfunctions.
• Parts that are broken, damaged, missing or worn
should be replaced immediately.
• Equipment should be cleaned periodically.
BOC stocks a huge range of personal protective
equipment. This, combined with BOC’s extensive
Gas and Gear network, ensures fast, reliable
service throughout the South Pacic.
STOP
PLEASE NOTE that under no circumstances should
any equipment or parts be altered or changed in
any way from the standard specication without
written permission given by BOC. To do so, will void
the equipmentwarranty.
Further information can be obtained from Weld
Australia (WTIA) Technical Note No.7
‘Health and Safety Welding’
Published by Weld Australia,
PO Box 6165 Silverwater NSW 2128
Phone [phone].

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BOC welding machines are designed and manufactured to conform
to IEC 60974 or AS 60974. This Standard not only covers themachine
but also the input cable and plug requirements including the size of
theplug that should be used.
X
Rated duty cycle
I0
Rated no-load
supply current
I1
Rated
supply current
AS 60974-1
Formula in clause 3.33
Maximum effective supply current
I1eff = √I12× X+ I02(1-X)
The I1e󹟽 determines thecorrect plug, input cable
andinput current required for each machine.
10A
I1eff ≤
I1eff ≤
I1eff ≤
I1eff ≤
1. 5 – 2. 5 m m 2
min – max cable size
size must be indicated
on the cable
15A 1. 5 – 4 m m 2
25A 2 . 5 – 6 mm 2
32A 4 – 10 m m 2
Before operating your welding machine, follow the instructions in the operating
manual. For more information refer to WTIA TN 22 – Welding Electrical Safety (Revised
2003) and WTIA TN 07 Health &Safety in Welding. If you have any queries please
contact BOC 131 262 (AU), 1800 111 333 (NZ).
Remember…
Switch on to
electrical safety
for single-phase equipment

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DO
Example
How important is the correct input cable and plug on
a welding machine?
The size of the plug depends on a formula that
not only uses the maximum current draw but
also the duty cycle of the power source. Theuse
of any welding power source will not only cause
the machine itself to heat up, but the input cable,
plug and mains power circuit will increase in
temperature as well. That’s why it’s important
to understand input and output currents and to
make sure that the input circuit is correctly rated
to supply the required input draw. Thisallows the
machine to operate at or near maximum output
and protects the circuit board from tripping,
overheating and/or catchingre.
Foryour safety, BOC meets AS/NZS Standards for
safe electricalcompliance.
Regulatory Compliance Mark
(RCM) andnumber
All BOC welding machines undergo an independent
certication process to meet Australian and New
Zealand regulations regarding electrical safety.
The triangle-circle-tick (RCM) symbol signies
that BOC has taken the necessary steps to have
the product comply with the electrical safety
and/or electromagnetic compatibility (EMC)
legislative requirements as specied by the
Electrical Regulatory Authorities Council (ERAC).
Depending on the machine, BOC may be required
to have a 32A single phase plug to ensure that
when the machine runs at its maximum output, the
input supply plug and lead will not overheat. For
your safety, please check for this symbol before
buying any welding machine in Australia and
NewZealand.
✓ Use the correct input current, ✓ cable and
✓ plug in accordance with AS60974-1 for your
safety and to get the maximum performance
from your welding machine.
If the I1e󹠢 rating on your machine is 27A
then you must use a 32A plug as a 15A
is undersized for the welding current
being used and may cause the cable to
overheat.

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Always
DON‘T
Example of BOC rating plateCheck the rating plate onyourmachine.
All welding machines that comply with IEC 60974
or AS 60974 must have a rating plate similar to the
one shown. Welding machines draw some current
when idle (not welding) and a higher current
when welding. E󹟽ective rated primary current
(I1e󹟽 ) combines the conductor heating due to
these two levels of current. I1e󹟽 is the maximum
rated e󹟽ective supply current that determines
the minimum plug and input cable rating as well
as the minimum capacity of the input circuit that
the machine gets plugged into to safely operate
the machine. Look for the I1e󹟽 on the welding
machine’s rating plate and ensure that you have
the correct input circuit to support this powerdraw.
What if I don’t have a 240volt 15 amp or
32 ampoutlet?
If you don’t have a suitable power outlet, you
should contact a qualied electrician to advise
whether the wiring in your building will cater for
a 15 amp or 32 amp outlet. You mayalso need
to upgrade your circuit breakers and possibly
switchboard to suit. Failure to do this may cause
an electrical re in the building which may
voidinsurances.
✖ Don’t risk damage to your machine or cause
tripping and/or re by using the wrong
input current, cable orplug.
✖ Don’t tamper with plugs or ledown earth
pins. Doing so willvoidwarranty.
✓ Inspect cables and plugs regularly.
✓ Contact a qualied electrician for advice
and/or upgrade and, if needed, to replace
any damaged plugs orcables.
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To set up your machine please ensure that the
power outlet is switched o󹟽 at the wall.
The Raptor 135 MIG is used as a ux-cored welder
using a 1kg spool of self-shielded wire and no
shielding gas.
The torch and work return lead are both
permanently tted and are not to be detached from
the welding machine.
3.1 How to set up your machine for
self-shielded flux-cored welding
Power Supply
1 phase~AC 240V
Workpiece
Earth clamp
Welding torch
Loading 1kg self-shielded flux-cored wire
Please wear safety glasses before loading wire
into your machine.
For gasless welding the machine will need to
be set up with self-shielded ux-cored wire as
illustrated below.
The welding torch is already installed. Press the
torch switch. In this case the wire is inched slowly
at a speed of 8m per minute. Release the switch to
stop wire inching.
Ensure your eyes and hands are well protected
from the wire coming out while inching.
A
C
B
A Plastic guide tube
B Drive rollers
C Rotate anti-clockwise
3.0 Installation

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3.2 How to install Shoulder Strap
The images shown here are indicative only. Ifthere
is any inconsistency between the image and the
actual product, the actual product shall govern.
Take the following parts to x the belt into the
machine.
Fix the belt as gure 1 to 3. The length of the
beltcan be adjusted as needed.
Figure 1
Figure 2
Figure 3

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INPUT
AC 240V
4.1 Control Panel 4.2 Back Panel
4.3 Operating instructions
The machine needs to be placed in a well-
ventilated area ensuring that the air vents are
notcovered.
For Flux-cored Welding.
1 Ensure correct personal protective equipment
is worn and that fume extraction and other
correct welding safety procedures are in place
before you begin.
2 Load your 1kg shelf-shielded wire according to
instructions found in 3.1.
3 Turn power on at the outlet (there is no on/o󹟽
switch on the machine).
4 Set the wire speed and voltage using the
welding power knob [1].
5 Begin welding.
4.0 Operation
1
5
2
3
4
6
IMPORTANT –
THERMAL PROTECTION
When the operation time of the machine
exceeds the rated duty cycle, the machine
may suddenly stop working due to
overheating. If this happens the red light on
the front of the machine panel will illuminate.
It is important to leave the machine switched
on so that the fans can continue to cool the
machine down. When the red light turns
o󹟽 the machine will, once again, be ready
forwelding.
1Welding power knob
2Power indicator
3Fault indicator
4Fixed welding torch lead*
5Fixed work return lead*
6Power lead
The illustrations shown here are
indicativeonly. The actual product
maydi󹠢er slightly.

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RAPTOR 135 MIG
Part No. RAPTOR135MIG
Input voltage Single phase AC 240V ±15%
Frequency 50 / 60 Hz
Rated input plug 10A
Maximum rated input current (I1max) 13 A
Maximum e󹠢ective supply current (I1e󹠢) 5.8 A
Output current adjustment range 45–100 A
Output voltage 16.3–19 V
Duty cycle 20% @ 90A
Power factor >0.7
E󹠣ciency ≥ 80%
Type of wirefeeder machine Internal
Gasless welding-wire diameter 0.8/0.9 mm
Insulation grade F
Protection grade IP21
Weight without wire (kg) 5.5 kg
Dimensions (L x W x H) 390x170x300 mm
Recommended generator rating 8 kVA
Standards AS/NZS 60974-1, IEC/EN 60974-10
5.0 Machine Specifications
Package Contents
• Powersource
• Work return lead (permanently tted to
machine)
• Welding torch (permanently tted to machine)
• Wire feed roller - Knurled groove 0.8-0.9

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6.1 Fundamentals of Gasless Flux
Cored ArcWelding
Welding technique
Successful gasless ux cored arc welding depends
on the following factors:
• Selection of correct consumables.
• Selection of the correct power source.
• Selection of the correct application techniques:
–Correct angle of electrode to work
–Correct electrical stick-out
–Correct travel speed
• Selection of the welding preparation.
Selection of correct consumables
Chemical composition
As a general rule, the selection of a wire is straight
forward, in that it is only a matter of selecting
an electrode of similar composition to the parent
material. However, there are certain applications
for which electrodes will be selected on the basis
of mechanical properties or the level of residual
hydrogen in the weldmetal.
The classication system for ux cored wires will
provide an indication of the residual hydrogen
level that can be expected in the weldmetal.
Physical condition
Surface condition
BOC ux cored wires are supplied as an in-line
baked product and therefore have a typical dark
surface appearance.
The wire must, however, be free from any surface
contamination, including surface rust. Most ux
and metal cored wires have a thin lm of graphite
on the surface of the wire to assist with feedability.
Selection of power source
Power sources for ux cored welding are selected
on a number of di󹟽erent criteria, including:
• Maximum output of the machine.
• Duty cycle.
• Output control (voltage selection, wire feed
speed control).
• Portability.
Correct application techniques
Direction of travel
Flux cored welding is normally performed using
a drag technique. The welding torch is tilted to
a 50-60° backhand angle. If, however, a atter
bead prole is required the backhand angle can
bereduced.
6.0 Basic Welding Techniques

15
WARNING
Always ensure that maintenance and testing is
carried out with the power switched o󹠢 at the
machine and poweroutlet.
The working environment or amount of use
the machine receives should be taken into
consideration when planning maintenance
frequency of your Raptor welder.
Preventative maintenance will ensure trouble-free
welding and increase the life of the machine and
its consumables.
7.1 Power Source
• Check electrical connections of unit at least
twice a year.
• Clean oxidised connections and tighten.
• Do not use any pressure-washing devices.
• Do not use compressed air as pressure may pack
dirt even more tightly into components.
• Only BOC authorised electricians should carry
out repairs and internal servicing.
7.2 Torch
• Always ensure that welding spatter is removed
from the torch nozzle and that the contact tip is
in good condition.
• Check that cable insulation is in good condition.
7.0 Periodic Maintenance

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8.0 Trouble Shooting
The following situations may happen due to certain
accessories used, welding material, environmental
inuences and power supply.
Problem Possible solution
Arc initiation di󹟾culty. Unstable arc. Check work return lead is connected properly to
the workpiece.
The output current fails to reach the ratedvalue. If your power supply voltage is inadequate you
may not achieve full welding current output.

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9.1 Terms of Warranty
BOC provides a warranty for the Raptor 135 MIG
sold by it against defects in manufacture and
materials.
Machines under warranty will be exchanged and
notrepaired.
• Valid for 2 years from date of purchase.
• Freight, packaging and insurance costs are to be
paid for by the claimant.
• No additional express warranty is given unless in
writing signed by an authorised manager of BOC.
• This warranty is in addition to any other legal
rights you may have.
• Electrode holders and torches are not covered.
9.2 Limitations on Warranty
The following conditions are not covered:
• Non compliance with operating and maintenance
instructions such as connection to incorrect
faulty voltage supply including voltage
surges outside equipment specs and incorrect
overloading.
• Natural wear and tear and accidental damage.
• Transport or storage damage.
The Warranty is void if:
• Changes are made to the product without the
approval of the manufacturer.
• Repairs are carried out.
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9.0 Warranty Information

MP20-0230 FDAUS 0321
BOC is a trading name of BOC Limited, a subsidiary of Linde plc. © BOC Limited 2021. Reproduction without permission is strictly prohibited. Details given in this document are
believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.
BOC Limited ABN 95 000 029 729
10 Julius Avenue, North Ryde NSW 2113, Australia
www.boc.com.au
BOC Limited NZBN 94 290 4095 3946
Building 6, Level 2, 666 Great South Road, Ellerslie, Auckland 1060, New Zealand
www.boc.co.nz
For more information contact the
BOC Customer Engagement Centre
on 131 262 (AU) or 0800 111 333 (NZ)