Linde BOC RAPTOR Bedienungsanleitung

•

180 TIG ACDC

Operating Manual

Welcome to a better way of welding

Congratulations on puchasing the Raptor 180 TIG ACDC 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 TIG 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.

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 Cylinder Safety 6

2.4 Electrical Shock 7

2.5 User Responsibility 7

Switch on to electrical safety 8

3.0 Package Contents 11

4.0 Connections 12

4.1 Power 12

4.2 Shielding gas 12

4.3 TIG torch connection 12

4.4 MMA operation 12

4.5 TIG welding operation 12

5.0 Control Panel and Display 14

5.1 Control Panel 14

5.2 Display symbols for MMA welding 15

5.3 Display symbols for TIG welding 15

6.0 Installation & Operation TIG welding 16

6.1 Installation for TIG welding 16

6.2 Starting up 17

6.3 Operation for TIG mode 17

6.4 Adjusting parameters 18

6.5 Start welding 19

6.6 DC current in TIG welding 19

7.0 Installation & Operation MMA welding 20

7.1 Installation for MMAwelding (DCEP) 20

7.2 Operation for MMA mode 21

7.3 Installing Adjustable Shoulder Strap 22

8.0 Machine Speciﬁcations 23

9.0 Gas Tungsten Arc Welding Process

(GTAW/TIG) 24

9.1 Introduction 24

9.2 Process 24

9.3 Process variables 25

9.4 Shielding gas selection 26

9.5 Welding wire selection 26

9.6 Tungsten electrode selection 27

9.7 Welding techniques 29

9.8

Torch movement during welding 29

9.9 Positioning torch tungsten for various

weldjoints 30

9.10 Joint preparation 31

10.0 TIG welding of materials 33

10.1 Application summary 33

10.2 C-Mn steel 33

10.3 Alloyed steel 34

10.4 Stainless steel 34

10.5 Copper and copper alloys 35

10.6 Welding Parameter for TIG 36

11.0 Manual Metal Arc Welding Process

(MMAW) 37

11.1 Process 37

11.2 Welding Machine 37

11.3 Welding Technique 38

11.4 Electrode Selection 38

11.5 Types of Joints 41

11.6 Fillet Welds 43

11.7 Typical Defects Due to FaultyTechnique 46

11.8 Welding Parameter for MMA 49

12.0 Periodic Maintenance 50

12.1 Power Source 50

13.0 Troubleshooting and Fault Finding 51

13.1 Environment 51

13.2 Problems During MMA Welding 51

13.3 Fault Finding 52

14.0 Warranty Information 53

14.1 Terms of Warranty 53

14.2 Limitations on Warranty 53

14.3 Warranty Period 53

14.4 Warranty Replacement 53

Contents

• 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:

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

2.3 Cylinder Safety

1Cylinder valve hand-wheel

2Back-plug

3Bursting disc

Back view of typical

cylinder valve

Operator wearing personal

protective equipment

(PPE) in safe position

Ten Points about Cylinder Safety

1Always read the labels and Safety Data Sheet

(SDS) before use.

2Store cylinders upright and use in

well-ventilated, secure areas away from

pedestrian or vehicle thoroughfares.

3Ensure cylinders are appropriately secured

and guarded against being knocked violently

or being allowed to fall.

4Wear safety shoes, glasses and gloves when

handling, connecting and using cylinders.

5Ensure cylinders are appropriately restrained

to mechanical lifting/handling devices prior

to movement.

6Keep in a cool, well-ventilated area, away

from heat sources, sources of ignition and

combustible materials, especially ammable

gases.

7Keep full and empty cylinders separate.

8Keep ammonia-based leak detection

solutions, oil and grease away from cylinders

and valves.

9Never use force when opening or closing

valves.

10 Never repaint or disguise markings and

damage on cylinders. If damaged, return

cylinders to BOC immediately.

Cylinder Valve Safety

When working with cylinders or operating

cylinder valves, ensure that you wear appropriate

protective clothing – gloves, boots and safety

glasses.

Ensure cylinder value is closed before moving or

disconnecting equipment.

Before operating a cylinder valve:

Ensure that the system you are connecting the

cylinder into is suitable for the gas and pressure

involved.

Cylinder valves should not be open unless a

pressure regulator has been tted.

Ensure that any accessories (such as hoses

attached to the cylinder valve, or the system being

connected to) are securely connected. Ahose, for

example, can potentially ail around dangerously

if it is accidentally pressurised when not restrained

at both ends.

Stand to the side of the cylinder so that neither

you nor anyone else is in line with the back of

the cylinder valve. This is in case a back-plug is

loose or a bursting disc vents. The correct stance is

shown in the diagram above.

When operating the cylindervalve

Open it by hand by turning the valve hand-wheel

anti-clockwise. Use only reasonable force.

Ensure that no gas is leaking from the cylinder

valve connection or the system to which the

cylinder is connected. DO NOT use ammonia-

based leak detection uid as this can damage

the valve. Approved leak detection uid, can be

obtained from a BOC Gas & Gear centre.

When nished with the cylinder, close the cylinder

valve by hand by turning the valve hand-wheel in

a clockwise direction. Use only reasonable force.

Remember NEVER tamper with thevalve. If

you suspect the valve is damaged, DONOT

use it. Report the issue to BOC and arrange

for the cylinderto be returned to BOC.

2.4 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 changing electrodes with bare

handsorwet gloves

• Never cooling electrode holders in water

• Working on a dry insulated oor where possible

• Never hold the electrode and holder under

yourarm.

2.5 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.

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 (02) 9748 4443.

STOP

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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.

Rated duty cycle

Rated no-load

supply current

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 ≤

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 mm2

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

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.

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 15amp 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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