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Linde BOC RAPTOR, Operating Manual

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Linde BOC RAPTOR Operating Manual Download Page 1

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180 TIG ACDC

Operating Manual

Summary of Contents for BOC RAPTOR

Page 1: ...2 2 y e a r conditional wa r r a n t y 2 y e a r conditional war r a n t y 180 TIG ACDC Operating Manual...

Page 2: ...onsibility 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 verified th...

Page 3: ...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...

Page 4: ...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 comin...

Page 5: ...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 effect on your health Don t breathe them in If you...

Page 6: ...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...

Page 7: ...rator and will void your warranty Only qualified personnel approved by BOC should perform repairs Always disconnect mains power before investigating equipment malfunctions Parts that are broken damage...

Page 8: ...y current I1eff I1 2 X I0 2 1 X The I1eff determines the correct plug input cable and input current required for each machine 10A I1eff I1eff I1eff I1eff 1 5 2 5mm2 min max cable size size must be ind...

Page 9: ...g machines undergo an independent certification process to meet Australian and New Zealand regulations regarding electrical safety The triangle circle tick RCM symbol signifies that BOC has taken the...

Page 10: ...ensure that you have the correct input circuit to support this power draw What if I don t have a 240volt 15amp or 32amp outlet If you don t have a suitable power outlet you should contact a qualified...

Page 11: ...11 3 0 Package Contents Package consists ofthe following Power source with input cable and plug Work return lead TIG torch MMA electrode holder and cable Regulator Gas hose Operating manual...

Page 12: ...ine by means of the Safe Lock dinse back end For DC TIG operation fit the torch back end to the negative dinse connection Similarly for DC fit the torch back end to the positive dinse connection The g...

Page 13: ...work piece In MMA mode connect with electrode holder 2 Remote Control socket Connected to torch control 3 Gas outlet Connect with TIG torch gas connector 4 Welding cable quick socket Negative output...

Page 14: ...mode The TIG mode includes TIG AC and TIG DC Remote indicator The indicator lights up when the parameters are set by the digital TIG torch or the foot control is connected 95 6 7 7 3 Menu button MMA m...

Page 15: ...e 1 6mm 4 0mm Hot start current Value range 20 to 20 Hot start time Value range 0 1s Arc force current Value range 20 to 20 5 2 Display symbols for MMAwelding Icon Name Suitable for Value range TIG AC...

Page 16: ...electric connector of TIG torch to welding machine s gas and electric socket and tighten firmly 5 Connect gas regulator to gas cylinder 6 Connect one end of gas hose to gas outlet of gas regulator Fas...

Page 17: ...ir in the gas tube is removed 6 2 Starting up Switch on the machine using the Power Switch The panel will display the previous settings that were saved in the last shutdown 6 3 Operation forTIG mode S...

Page 18: ...button 95 6 7 7 3 for 3 seconds Select the parameters to be set by pressing the welding menu button 95 6 7 7 3 and then adjusting the parameter value using the Adjustment Knob Figure 8 The Start Curr...

Page 19: ...IG position For DC Pulse TIG welding DC welding of thin material can further be enhanced by using the pulse mode When using the pulse mode for DC applications the current will be varied between the we...

Page 20: ...welding machine 5 Press the bottom left button to select function MMA 7 0 Installation Operation MMA welding 4 3 2 1 Please check the welding electrode manufacturer s polarity recommendation before co...

Page 21: ...nel to choose MMA mode MMA symbol will show on the display Set VRD function Under the MMA mode press the menu button 95 6 7 7 3 for 3 seconds and then release to turn off Figure 17 or turn on Figure 1...

Page 22: ...22 7 3 Installing Adjustable Shoulder Strap 1 2 3 4...

Page 23: ...ve supply current I1eff 9 4A 9 1A 9 9A Output current 15 160A 20 180A 20 160A Output voltage 10 6 16 4V 10 8 17 2V 20 8 26 4V Duty cycle 15 160A 10 180A 8 160A 60 80A 60 74A 60 58A 100 62A 100 57A 100...

Page 24: ...racteristics are normally employed to supply the welding current For DC operation the tungsten may be connected to either output terminal but is most often connected to the negative pole The output ch...

Page 25: ...aight polarity is used mainly for welding Carbon steels Stainless steels Copper alloys The increased amperage provides Deeper penetration Increased welding speed A narrower deeper weld bead DCEP Wide...

Page 26: ...on Small concentrated HAZ Magnesium alloys Argon Used with continuous high frequency AC Good arc stability Good cleaning action Stainless steel Argon Good penetration Good arc stability Helium Deeper...

Page 27: ...o spitting Consistent arc starts Good stability Mild Steels Carbon Steels Alloy Steels Stainless Steels and Titanium alloys All General purpose DCSP 2 Thoriated EW Th2 75 Argon 25 Helium Best stabilit...

Page 28: ...ip shapes and current ranges Thoriated ceriated and lanthanated tungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes and as such are typically used for DCSP welding Th...

Page 29: ...eld 60 75 from the metal surface This is the same as holding the torch 15 30 from the vertical Take special note that the rod is in the shielding gas during the welding process 9 8 Torch movement duri...

Page 30: ...0 20 10 15 75 90 15 75 90 20 70 20 10 15 75 15 75 20 70 15 75 T Joint 90 20 40 15 75 90 20 70 20 10 15 75 15 75 20 70 20 10 15 75 75 90 20 40 15 7 90 20 20 10 15 75 CornerJoint 15 75 90 20 40 30 15 75...

Page 31: ...2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 20 6 15 r s 2 s 2 3 0 S 2 3 0 3 4 12 2 1 1 5 3 6 20 50 2 3 5 1 3 20 10 60 2 3 5 5 16 10 2 8 40 1 5 3 50 50 15 40 3 20 6 3 15 r s 2 s 2 3 0 S...

Page 32: ...des Long arc length Acute angle Loss of gas coverage Angular mis alignment Unsymmetrical bead profile Mis alignment Incomplete penetration Filler rod removed from gas shield Tungsten inclusions Tungst...

Page 33: ...od workpiece heating Only inert or reducing gases should be used for TIG welding and pure argon is normally recommended as the shielding gas for steel Filler rods are usually selected to match the che...

Page 34: ...0 4 8 6 4 Gas flow l min 3 4 3 4 4 4 5 4 6 5 6 5 6 5 7 Current A 30 60 70 100 90 110 120 150 190 250 220 340 300 360 350 450 Consumable size mm 1 0 1 6 1 6 2 0 2 0 3 2 3 2 4 0 4 0 6 0 4 0 6 0 4 0 6 0...

Page 35: ...y in thicker sections Pure argon is the shielding gas used for AC TIG welding TIG consumables are solid filler rods based on pure copper and several copper alloy compositions including aluminium bronz...

Page 36: ...0 2 5 2 0 8 10 10 12 8 10 3 0 4 0 120 170 2 5 3 0 2 5 10 12 10 15 10 12 4 0 160 200 3 0 3 0 10 14 12 18 12 14 Reference welding process of AC TIG welding of aluminum alloy Thickness of workpiece mm Cu...

Page 37: ...and then the other Similarly the voltage in the circuit changes from positive to negative with changes in direction of current flow This complete reversal is called a half cycle and repeats as long as...

Page 38: ...eed correct preparation of work to be welded 11 4 Electrode Selection As a general rule the selection of an electrode is straight forward in that it is only a matter of selecting an electrode of simil...

Page 39: ...eans that if 1 5 mm sheet is being welded 2 0 mm diameter electrode is the recommended size The following table gives the recommended maximum size of electrodes that may be used for various thicknesse...

Page 40: ...to ensure a smooth even transfer of metal The recommended angles for use in the various welding positions are covered later Correct Travel Speed The electrode should be moved along in the direction o...

Page 41: ...scribed as follows Square Butt Weld WELD BEADS The edges are not prepared but are separated slightly to allow fusion through the full thickness of the steel Suitable for plate up to 6mm in thickness S...

Page 42: ...welding from both sides For a given thickness it is faster needs less weld metal and causes less distortion than a single U preparation Horizontal Butt Weld The lower member in this case is bevelled t...

Page 43: ...ct procedure for welding thick plate when using multiple runs Electrode Angle for 1st and 2nd Layers WELD BEADS LAYERS WELD BEADS LAYERS S WELD META Electrode Angle for Subsequent Layers WELD BEADS LA...

Page 44: ...e fitted as shown leaving a V shaped groove in which a fillet weld is deposited Fusion should be complete for the full thickness of the metal In practice it is generally necessary to have a gap or a s...

Page 45: ...ssive speed will produce a narrow irregular run having poor penetration and where larger electrodes and high currents are used undercut is likely to occur Fillet Weld Data Nominal Fillet Size mm Minim...

Page 46: ...ight runs or several wide weaving runs Correct selection of electrodes is important for verticalwelding In overhead fillet welds careful attention to technique is necessary to obtain a sound weld of g...

Page 47: ...de angle Undercutting UNDERCUTTING Undercutting is a groove melted in the base metal next to the toe or root of a weld that is not filled by the weld metal Undercutting causes a weaker joint and it ca...

Page 48: ...a multiple pass weld Causes of this defect can be excessive travel speed electrode size too large welding current too low poor joint preparation letting the weld metal get ahead of the arc Lack of fu...

Page 49: ...basic electrode E4315 J427 E4316 J426 E5015 J507 E5016 J506 E5018 J506LMA E5015 G J507R E5015 G J507RH E5515 G J557 E6015 D1 J607 E8015 G J807 E8515 G J857CrNi E9015 G J907 DCEP Flat position 2 5 50 9...

Page 50: ...ean oxidised connections and tighten Inner parts of machine should be cleaned with a vacuum cleaner and soft brush Do not use any pressure washing devices Do not use compressed air as pressure may pac...

Page 51: ...tion of the power source shall not exceed 10 The environment where the equipment is stored should be clean and protected from sand and dust Dust acids corrosive gases or substances in the surrounding...

Page 52: ...on 2 The circuit of auxilliary power supply is broken 1 The machine will automatically return to normal in 5 10 minutes 2 Contact BOC or authorised service agent 5 1 The text in the panel is incorrect...

Page 53: ...not limited to daily allowances or accommodation and travelling costs Modification of the 10A primary input plug or fitment of another primary input plug will render the warranty null and void NOTE U...

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Page 56: ...t 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 Au...

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