IM6016 REDI-MIG®Plus215C,255C,255S Page1

Complete your warranty registration online for your chance to win a Lincoln Electric welding helmet valued at $299 – one winner drawn each month – and the chance to win a Hot Lap with V8 Supercar driver Jason Bright*.

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Safety Depends on You Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation on your part. Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual.

Most importantly, think before you act and be careful.

REDI-MIG® Plus 215C, 255C, 255S Operator’s Manual

IM6016May 2010

Lincoln Electric® Australasia

Part No. Description Volts

K32061-11 REDI-MIG® Plus 215C 240

K32062-11 REDI-MIG® Plus 255C 240

K32062-2- AUP REDI-MIG® Plus 255S 240

This manual applies to

Page2 REDI-MIG®Plus215C,255C,255S IM6016

ARCWELDINGSAFETYPRECAUTIONS 3 WELDING,EMF&PACEMAKERS 5 INSTRUCTIONSFORELECTROMAGNETICCOMPATIBILITY 6 Section1 INSTALLATION 8 1.1 Location 8 1.2 ConnectiontoMainsSupply 8 1.3 ShieldingGasSupply(fortheGasMetalArcWeldingProcess) 9 1.4 GunandCableInstallation 9 1.5 OutputPolarityConnection 9

Section2 OPERATINGINSTRUCTIONS 10 2.1 DutyCycle 10 2.2 ControlPanel 10

Section3 SETTINGUPFORWELDING 14

Section4 WELDING 17 4.1 ChangingElectrodeSizeandType 17 4.2 AdjustingSpoolTension 17

Section5 LEARNINGTOWELD 17 5.1 TheArc-WeldingCircuit 17 5.2 TheSelf-Shielded(Gasless)FCAWWeldingArc 18 5.3 TheGMAW(MIG)WeldingArc 18 5.4 ProcessSelection 18 5.5 CommonMetals 18 5.6 MachineSetUpfortheSelf-Shielded(Gasless)FCAWProcess 18 5.7 WeldingTechniquesfortheSelf-Shielded(Gasless)FCAWProcess 19 5.8 MachineSetUpfortheGMAW(MIG)andGas-ShieldedFCAWProcesses 20 5.9 WeldingTechniquesfortheGMAW(MIG)Process 20 5.10 JointTypesandPositions 21 5.11 ButtWelds 21 5.12 Penetration 21 5.13 FilletWelds 22 5.14 WeldingintheVerticalPosition 22 5.15 Vertical-UpandOverheadWelding 22 5.16 Vertical-DownWelding 22 5.17 TroubleshootingWelds 22

Section6 MAINTENANCE 23 6.1 RoutineMaintenance 23 6.2 GunandCableMaintenance 23 6.3 GunTipsandNozzles 23 6.4 InputLead 23 6.5 LinerRemoval,InstallationandTrimmingInstructions forLINCGun®240&360Torch 24

Section7 ACCESSORIES 24

Section8 GROUNDTESTPROCEDURE 24Section9 TROUBLESHOOTING 26

INDEX

IM6016 REDI-MIG®Plus215C,255C,255S Page3

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.

ARC WELDING SAFETY PRECAUTIONS

1. a. The electrode and work (or ground) circuits areelectrically“hot”whenthewelder ison.Donottouchthese “hot”partswithyourbareskinorwetclothing.Weardry,hole-freeglovestoinsulatehands.

b. In semi-automatic and automatic wire welding, theelectrode,electrodereel,weldingheadandnozzleorsemi-automaticweldinggunarealsoelectrically“hot”.

c. Insulate yourself from work and ground using dryinsulation.Whenweldingindamplocations,onmetalframework such as floors, gratings or scaffolds, andwhen in positions such as sitting or Lying, makecertaintheinsulationislargeenoughtocoveryourfullareaofphysicalcontactwithworkandground.

d. Always be sure the work cable makes a goodelectricalconnectionwiththemetalbeingwelded.Theconnectionshouldbeascloseaspossibletotheareabeingwelded.

e. Ground the work or metal to be welded to a goodelectrical(earth)ground.

f. Maintain the electrode holder, work clamp, weldingcable and welding machine in good, safe operatingcondition.Replacedamagedinsulation.

g. Neverdiptheelectrodeholderinwaterforcooling. h. Never simultaneously touchelectrically “hot” parts of

electrodeholdersconnected to twoweldersbecausevoltagebetweenthetwocanbethetotaloftheopencircuitvoltageofbothwelders.

i. Whenworkingabovefloorlevel,protectyourselffromafallshouldyougetashock.

j. Alsoseeitems4cand6.

2. a. Weldingmayproducefumesandgaseshazardoustohealth.Avoidbreathingthesefumesandgases.Whenwelding,keepyourheadoutofthefume.Useenoughventilationand/orexhaustatthearctokeepfumesandgases away from the breathing zone.Whenweldingongalvanised,leadorcadmiumplatedsteelandothermetalswhichproducetoxicfumes,evengreatercaremustbetaken.

b. Donotweldinlocationsnearchlorinatedhydrocarbonvapourscomingfromdegreasing,cleaningorsprayingoperations.Theheatandraysofthearccanreactwithsolventvapourstoformphosgene,ahighlytoxicgas,andotherirritatingproducts.

c. Shielding gases used for arc welding can displaceair and cause injury or death. Always use enoughventilation, especially in confined areas, to ensurebreathingairissafe.

d. Readandunderstandthemanufacturer’sinstructionsfor thisequipmentand theconsumables tobeused,including thematerial safetydatasheet (MSDS)andfollowyouremployer’ssafetypractices.

e. AlsoseeItem7b.

3. a. Use a shield with the proper filter and cover platestoprotectyoureyes fromsparksand the raysof thearc when welding or observing open arc welding.Headshield and filter lens should conform to AS1674.2-1990standards.

b. Use suitable clothing made from durable flameresistantmaterialtoprotectyourskinandthatofyourhelpersfromthearcrays.

c. Protect other nearby personnel with suitable nonflammable screening and/orwarn themnot towatchthearcorexposethemselvestothearcraysortohotspatterormetal.

4. a. Removefirehazards fromtheweldingarea. If this isnotpossible,coverthemtopreventtheweldingsparksfrom starting a fire. Remember that welding sparksandhotmaterialsfromweldingcaneasilygothroughsmallcracksandopeningstoadjacentareas.Haveafireextinguisherreadilyavailable.

b. Where compressed gases are to be used at the jobsite, special precautions should be used to preventhazardous situations. Refer to AS1674 Parts 1 &2 “Safety in Welding and Allied Processes”, WTIATechnicalNote7“HealthandSafetyinWelding”andthe operating information for the equipment beingused.

c. When not welding, make certain no part of theelectrode circuit is touching the work or ground.Accidentalcontactcancauseoverheatingandcreateafirehazard.

d. Do not heat, cut orweld tanks, drums or containersuntil theproperstepshavebeentakento insure thatsuch procedures will not cause flammable or toxicvapoursfromsubstancesinside.Thesecancauseanexplosioneventhoughthevesselhasbeen“cleaned”.ForinformationrefertoAS1674.1&.2(latesteditions).

e. Vent hollow castings or containers before heating,cuttingorwelding.Theymayexplode.

f. Sparksandspatterare thrown from theweldingarc.Wear oil free protective garments such as leathergloves,heavyshirt,cufflesstrousers,highshoesandacapoveryourhair.Wearearplugswhenweldingoutofpositionor inconfinedplaces.Alwayswearsafetyglasseswithsideshieldswheninaweldingarea.

g. Connect thework cable to thework as close to theweldingareaaspossible.Work cables connected tothe building framework or other locations away fromtheweldingareaincreasethepossibilityoftheweldingcurrentpassingthroughliftingchains,cranecablesorotheralternatecircuits.Thiscancreatefirehazardsoroverheatliftingchainsorcablesuntiltheyfail.

h. AlsoseeItem7c.

FUMES AND GASEScan be dangerous

ARC RAYS can burn

WELDING SPARKS cancause fire or explosion

Page4 REDI-MIG®Plus215C,255C,255S IM6016

5. a. Use only compressed gas cylinders containingthe correct shielding gas for the process used andproperly operating regulators, designed for the gasandpressureused.Allhoses, fittings,etc.shouldbesuitable for the application and maintained in goodcondition.

b. Always keep cylinders in an upright position andsecurely chained to an undercarriage or fixedsupport.

c. Cylindersshouldbelocated: • Away from areas where they may be struck or

subjectedtophysicaldamage. • A safe distance from arc welding or cutting

operations and any other source of heat, sparksorflame.

d. Never allow the electrode, electrode holder, or anyotherelectrically“hot”partstotouchacylinder.

e. Keepyourheadandfaceawayfromthecylindervalveoutletwhenopeningthecylindervalve.

f. Valve protection caps should always be in placeandhand-tightexceptwhen thecylinder is inuseorconnectedforuse.

g. Readand follow the instructionsoncompressedgascylinders and associated equipment, and AS 2030Parts1&2.

6. a. Turnoffinputpowerusingthedisconnectswitchatthefuseboxbeforeworkingontheequipment.

b. Installequipment inaccordancewith theSAAWiring Rules,all localcodesandthemanufacturer’srecom-mendations.

c. Earth the equipment in accordance with the SAAWiring Rules and the manufacturer’s recommenda-tions.

7. a. Turn the engine off before troubleshoot-ing and maintenance work unless themaintenance work requires it to berunning.

b. Operate engines in open, well ventilatedareas or vent the engine exhaust fumesoutdoors.

c. Donotaddfuelnearanopenflame,weldingarcorwhentheengineisrunning.Stoptheengineandallowittocoolbeforerefuellingtopreventspilled fuel fromvaporizingoncontactwithhotenginepartsandigniting.Donotspillfuelwhenfillingtank.Iffuelisspilled,wipeitupanddonotstartengineuntilfumeshavebeeneliminated.

d. Keepallequipment,safetyguards,coversanddevicesinpositionandingoodrepair.Keephands,hair,clothingandtoolsawayfrom V-belts, gears, fans and all othermoving partswhen starting, operating orrepairingequipment.

e. In some cases it may be necessary toremovesafetyguardstoperformrequiredmaintenance.Removeguardsonlywhennecessary and replace them when themaintenance requiring their removal iscomplete. Always use the greatest carewhenworkingnearmovingparts.

f. Donotputyourhandsneartheenginefan.Donotattempttooverridethegovernororidlerbypushingonthethrottlecontrolrodswhiletheengineisrunning.

g. To prevent accidentally starting petrolengineswhileturningtheengineorweldinggenerator during maintenance work,disconnectthesparkplugwires,distributorcapormagnetowireasappropriate.

h. To avoid scalding do not remove theradiatorpressurecapwhentheengine ishot.

CYLINDER may explode if damaged

FOR ELECTRICALLY powered equipment

FOR ENGINE powered equipment

HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE

HOWTOORDERREPLACEMENTPARTSToensurethatyoureceivethecorrectreplacementpartthefollowingprocedureshouldbefollowed: 1. QuoteSerialNumberandCodeNumber. 2. QuotetheDescription, ItemNumberandPartsListNumberof thedesiredpart.Whenorderingparts for itemscarryingbrand

namesofothercompanies,suchasfanmotors,driveshafts,etc.,besuretoincludetheothercompany’snameandpartnumberandotherrelevantinformation.

3. Shouldtheprimarycordbedamaged,aspecialcordisrequired,andisavailablefromLincolnElectric. 4. PartsshouldbeorderedfromLincoln,itsofficesorthenearestAuthorisedFieldServiceShop.(The“LincolnServiceDirectory”

listingtheseshopsgeographicallyisavailableonrequest.)Note:“Hardware”intheLincolnPartsListsarenotLincolnstockitemsbutcanbeobtainedviatheFieldServiceShopnetwork.Component parts of assemblies such as stator coils or armature coils, etc., which require electrical testing or locating fixtures arenot considered replaceable items.This is toensure that the customer receivespartswhichwill keep thewelder in thebest operatingcondition.

BUYONLYGENUINEREPAIRPARTS

Formoredetailedinformationitisstronglyrecommendedthatyoupurchaseacopyof“SafetyinWeldingandCutting-ANSIStandardZ49.1”andWTIATechnicalNote7.AllWTIApublicationsandANSI/AWSStandardsareavailablefromtheWeldingTechnologyInstituteofAustralia,P.O.Box6165,SilverwaterNSW2128.ForcopiesofvariousAustralianStandardscontactyourlocalS.A.A.office.Formoredetailedinformationitisstronglyrecommendedthatyoureviewcopiesof“SafetyinWeldingandAlliedprocesses-AS1674.1&.2”andWTIATechnicalNote7–TN07.AustralianStandardsareavailablefromSAIGlobal–www.saiglobal.comandWTIApublicationsareavailablefromtheWeldingTechnologyInstituteofAustralia–www.wtia.com.au.

IM6016 REDI-MIG®Plus215C,255C,255S Page5

WELDING, EMF & PACEMAKERSAll welders should follow safe practices that minimise theirexposuretoelectricandmagneticfields(EMF).

For welders wearing implanted pacemakers, safe weldingpractices are particularly important and additional proceduresshould be followed by those who have decided to continue toweld.(Hopefullyinkeepingwithadoctor’sadvice).

Thefollowingprocedureswillnoteliminateexposure toEMForthepossibilityofarcweldinghavinganeffectonapacemaker,however if followed, they will significantly reduce exposure toelectric and magnetic fields. Electric and magnetic fields arecreated any time electric current flows through a conductor,however it is not clear whether such exposure affects oneshealth.

Some researchers have reported that exposure to EMF maycauseleukemiaorotherillnesses.Theseclaimsoriginallyaroseinrelationtohighvoltageelectricpowerlinesandareverymuchindispute in themedicalandscientificarena,howeverthebestadviceistominimiseyourexposuretoEMFtoprotectyourhealthshoulddoctorseventuallydecidethereisarisk.

TherearefourfundamentalfactsaboutEMF:• With direct current (DC), the field strength is relatively

constantanddoesnotchange.• Withalternatingcurrent(AC),thefieldstrengthconstantly

changes.• Thegreaterthecurrentflow,i.e.thehighertheamps,the

strongerthefieldcreatedbythecurrent• Theclosertheconductororelectricaldeviceistothebody,

thegreatertheexposuretothefield.

Minimising exposure

AllweldersshouldusethefollowingprocedurestominimiseEMFexposure.

• Routeelectrodeorgunandworkcablestogether.Securethemwithtapeifpossible.

• Nevercoiltheelectrodeleadaroundyourbody.• Donotplaceyourbodybetween theelectrodeandwork

cables.Ifyourelectrodecableisonyourrightsidetheworkcableshouldalsobeonyourrightside.

• Connect the work cable to the work piece as close aspossible to the area being welded. (This is also a goodpractice to eliminate a common problem on welding - apoorworkconnection.

• Donotworknexttotheweldingpowersource.

Welders with pacemakers

There isnoquestion that the fields inarcweldingcan interferewithapacemakersfunction.Generallytheinterferencedoesnotpermanentlydamagethepacemaker.Oncethewearerleavesthearcweldingenvironmentorstopswelding,thepacemakerreturnstonormal functioning.Theweldingarchas littleornoeffectontheoperationof somepacemakers,especiallydesigns thatarebi-polarordesignedtofilteroutsuchinterference.

Forawelderoranyoneworkingaroundelectricalequipmenttheselectionofapacemakerisveryimportant.Getadoctor’sadviceaboutwhichpacemakeristheleastsensitivetointerferencefromweldingwhilestillbeingmedicallysuitable.

Inadditiontothenormalsafetyprecautions,thefollowingadditionalproceduresshouldbeadoptedbywelderswithpacemakers.• Usegasweldingwhentheapplicationissuitable.• Use the lowest current setting appropriate for the

application. Do not exceed 400 amps. Low current(75-200amps)directcurrent(DC)weldingshouldbeusedif arc welding is necessary. Do not TIG weld with highfrequency.

• Donotuserepeated,shortwelds.Waitabouttensecondsbetween stopping oneweld and starting the next.Whenhavingdifficultystartinganelectrode,donot re-strike therodrepeatedly.

• If you feel light headed, dizzy or faint, immediately stopwelding.Laytheelectrodeholderdownsothatitdoesnotcontacttheworkandmoveawayfromanyweldingbeingperformed.Arrange yourwork in advance so that, if youbecomedizzyanddroptheelectrodeholder,theelectrodeholderwillnotfallonyourbodyorstrikethework.

• Donotworkonaladderorotherelevatedpositionorinacramped,confinedplace.

• Do not work alone. Work only in the presence of anindividual who understands these precautions and thepossibleeffectweldingmayhaveonyourpacemaker.

• Donotworknearspotweldingequipment.• Ifyouhaveapacemakerandwishtocontinuearcwelding,

discuss this andanyother questions youmayhavewithyour physician and follow his or her advice. The doctormay wish to contact the pacemaker manufacturer for arecommendation.Asmentionedbefore, thedesignof thepacemaker significantly affects the degree to which it issubject to interference fromaweldingcircuit.Donot relyonthefactthatyouknowanotherwelderwithapacemakerwhohasweldedforyearswithoutexperiencingaproblem.That welder and his or her pacemaker may be quitedifferentfromyouandyourpacemaker.

Page6 REDI-MIG®Plus215C,255C,255S IM6016

ConformanceProducts displaying the C-Tick mark are in conformity withAustralian/New Zealand requirements for ElectromagneticCompatibility(EMC).Theyare:• manufactured in conformity with Australian/New Zealand

Standard (Emission):- AS/NZS 3652 ‘ElectromagneticCompatibility - ArcWelding Equipment’ (Identical to andreproducedfromBritishStandardEN50199)

• forusingwithotherLincolnElectric/LiquidArcequipment.• designedforindustrialandprofessionaluse.

IntroductionAll electrical equipment generates small amounts of electro-magnetic emission. Electrical emission may be transmittedthroughpowerlinesorradiatedthroughspace,similartoaradiotransmitter.When emissions are received by other equipment,electrical interference may result. Electrical emissions mayeffectmanykindsofelectricalequipment:othernearbyweldingequipment, radio and TV transmitters and receivers, numericalcontrolled machines, telephone systems, computers, etc. Beaware that interference may result and extra precautions mayberequiredwhenaweldingpowersourceisusedinadomesticestablishment.

Installation and UseThe purchaser/user is responsible for installing and using theweldingequipmentaccordingtothemanufacturer’s instructions.Ifelectromagneticdisturbancesaredetectedthenitshallbetheresponsibility of the purchaser/user of the welding equipmentto resolve the situation with the technical assistance of themanufacturer. In some cases this remedial action may be assimple as earthing (grounding) the welding circuit (see notebelow). In other cases it could involve constructing an elec-tromagnetic screen enclosing the power source and the workcomplete with associated input filters. In all cases electromag-neticdisturbancesmustbereducedtothepointwheretheyarenolongertroublesome.Note:Theweldingcircuitmayormaynotbeearthedforsafetyreasons according to national codes. Changing the earthingarrangements should only be authorised by a person who iscompetent to assesswhether the changes increase the risk ofinjury,eg.byallowingparallelweldingcurrentreturnpathswhichmaydamagetheearthcircuitsofotherequipment.

Assessment of AreaBefore installing welding equipment the purchaser/user shallmake an assessment of potential problems in the surroundingarea.Thefollowingshallbetakenintoaccount:a. Other supply cables, control cables, signalling and

telephonecablesabove,belowandadjacenttotheweldingequipment;

b. Radioandtelevisiontransmittersandreceivers;c. Computerandothercontrolequipment;d. Safetycriticalsafetyequipment,eg.guardingofindustrial

equipment;e. Thehealthofpeoplearound,eg. theuseofpacemakers

andhearingaids;;f. Equipmentusedforcalibrationormeasurement;g. Theimmunityofotherequipmentintheenvironment.The

purchaser/user shall ensure that other equipment beingused in theenvironment is compatible. Thismay requireadditionalprotectionmeasures;

h. Thetimeofthedaythatweldingorotheractivitiesaretobecarriedout.

The sizeof the surroundingarea to be consideredwill dependonthestructureofthebuildingandotheractivitiesthataretakingplace.Thesurroundingareamayextendbeyondtheboundariesofthepremises.

Methods of Reducing EmissionsMains SupplyWelding equipment should be connected to the mains supplyaccordingtothemanufacturer’srecommendations.Ifinterferenceoccurs,itmaybenecessarytotakeadditionalprecautionssuchas filtering the mains supply. Consideration should be givento shielding the supply cable of permanently installed weldingequipmentinmetallicconduitorequivalent.Shieldingshouldbeelectricallycontinuousthroughoutitslength.Theshieldingshouldbeconnectedtotheweldingpowersourcesothatgoodelectricalcontactismaintainedbetweentheconduitandtheweldingpowersourceenclosure.

Maintenance of the Welding EquipmentTheweldingequipmentshouldberoutinelymaintainedaccordingto themanufacturer’srecommendations.Allaccessandservicedoorsandcoversshouldbeclosedandproperlyfastenedwhenthe welding equipment is in operation. Thewelding equipmentshould not be modified in any way except for those changesand adjustment covered in the manufacturer’s instructions.In particular, the spark gaps of arc initiation and stabilisingdevices should be adjusted and maintained according to themanufacturer’srecommendations.

Welding CablesThe welding cables should be kept as short as possible andshould be positioned close together, running at or close to thefloorlevel.

Equipotential BondingBonding of all metallic components in the welding installationand adjacent to it should be considered. However, metalliccomponentsbondedtotheworkpiecewillincreasetheriskthatthe operator could receive a shock by touching these metalliccomponents and the electrode at the same time. The operatorshouldbeinsulatedfromallsuchbondedmetalliccomponents.

Earthing of the workpieceWheretheworkpieceisnotbondedtoearthforelectricalsafety,norconnectedtoearthbecauseofitssizeandposition,eg.ship’shull or building steelwork, a connection bonding theworkpieceto earthmay reduce emissions in some, but not all instances.Care should be taken to prevent the earthing of work piecesincreasingtheriskofinjurytousers,ordamagetootherelectricalequipment.Wherenecessary,theconnectionoftheworkpiecetoearthshouldbemadebydirectconnectiontotheworkpiece,butinsomecountrieswheredirectconnection isnotpermitted, thebonding should be achieved by suitable capacitance, selectedaccordingtonationalregulations.

Screening and ShieldingSelectivescreeningandshieldingofothercablesandequipmentin thesurroundingareamayalleviateproblemsof interference.Screening of the entirewelding installationmay be consideredforspecialapplications.** Portions of the preceding text are contained in AS/NZS3652:

‘ElectromagneticCompatibility-ArcWeldingEquipment’.

INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY

Thisweldingmachinemustbeusedbytrainedoperatorsonly.Readthismanualcarefullybeforeattemptingtousetheweldingmachine.

WARNING

IM6016 REDI-MIG®Plus215C,255C,255S Page7

Pleaserecordyourequipmentidentificationinformationbelowforfuturereference.Thisinformationcanbefoundonyourmachinenameplate.

ModelName&Number ________________________________________

Code&SerialNumber ________________________________________

DateofPurchase ________________________________________

Wheneveryourequestreplacementpartsorinformationonthisequipment,alwayssupplytheinformationyouhaverecordedabove.

Thank YouforselectingaQUALITYproductbyLincolnElectric.WewantyoutotakeprideinoperatingthisLincolnElectricCompanyproduct-asmuchprideaswehaveinbringingthisproducttoyou!

ReadthisOperator’sManualcompletelybeforeattemptingtousethisequipment.Savethismanualandkeepithandyforquickreference.Payparticularattention to theSafety Instructionswehaveprovidedforyourprotection.The levelofseriousnesstobeappliedtoeachisexplainedbelow:

This statement appears where the information must befollowed exactly to avoid serious personal injury or lossoflife.

WARNINGThis statement appears where the information must befollowedtoavoidminorpersonal injuryordamagetothisequipment.

CAUTION

Page8 REDI-MIG®Plus215C,255C,255S IM6016

Machine Installation1.1 Location Place the welder where clean cooling air can freely

circulateinthroughthebacklouversandoutthroughthefrontlouvres.Dirt,dustoranyforeignmaterialthatcanbedrawnintotheweldershouldbekeptataminimum.Failureto observe these precautions can result in excessiveoperatingtemperaturesandnuisancethermostattrips.

1.2 Connection to Mains Supply Beforeconnectingthemachinetothemainssupplycheck

that the voltage and current capacity correspond to themachinevoltageandratedinputcurrent.UseafuseorC/BperAS3000orlocalwiringrules.

Themachineissuppliedwithaninputleadfitted. Haveaqualifiedelectricianfitasuitableinputplug. The REDI-MIG® Plus 215C, 255C and 255 are supplied

withfactoryfitted240volt15ampplug.

•Turntheinputpoweroff at t hedisconnectswitchbeforeinstallingorservicingthismachine.

•Donottouchelectrically“hot”partssuchasoutputterminalsorinternalwiring.

•Connectearthingscrew()toagoodearthground.

•Donotoperatewithcovers removed.

•Turnpowerswitch“off”beforeconnectingordisconnectingcablesorotherequipment.

WARNING

HIGHVOLTAGEcankill

Onlyqualifiedpersonnelshouldinstallorservicethisequipment.

PRODUCT DESCRIPTIONTheREDI-MIG®Plus family is the latest development in step controlledMIGweldingmachinesdesignedandbuilt by LincolnElectric.LincolnElectric’snewREDI-MIG®Plusfamilycomprisesofthreemodelsinbothcompactandseparatewirefeeder.TheREDI-MIG®Plus215C,255Cand255Sarefor240voltsupply.Excellentarccharacteristicsareprovidedforgasshieldedandselfshieldedweldingwithintherespectivemachine’scurrentranges.

Section 1 - INSTALLATION

Never connect the green/yellow conductor to any of theactive supply lines from themains. This conductor is toearth themachine as required byElectricalRegulations.Once the above has been followed the machine can bepluggedintothemainsoutlet.

Specifications 215C 255C 250S PWF4-S

Part No. K32061-11 K32062-11 k32062-2-AUP K32066-1

Maximum Open Circuit Voltage

35V 38V 38V

Output Current Range 30-220A 30-255A 30-255A

Duty Cycle 220A/25V @ 15%130A/20.5V @ 60%100A/19V @ 100%

255A/26.8V @ 20%150A/21.5V @ 60%120A/20V @ 100%

255A/26.8V @ 20%150A/21.5V @ 60%120A/20V @ 100%

Rated Input AS60974.1 240V 1 phase 50/60Hz 15 amp

240V 1 phase 50/60Hz 25 amp

240V 1 phase 50/60Hz 25 amp

42V AC5 amp

Wire Speed Range 1-20 m/min 1-20 m/min 1-20 m/min 1-20 m/min

H x W x L (mm) Over handle

765 x 427 x 850 765x427x850 765x427x850* 490x350x420

Operating Temperature -20°C to 40°C -20°C to 40°C -20°C to 40°C -20°C to 40°C

IP Rating IP23 IP23 IP23 IP23

Weight (complete with u/c)

87kg 87kg 108kg* 15kg

* Weights and dimensions for the 255S do not include the PWF4S wire feeder. These need to be added for total package

IM6016 REDI-MIG®Plus215C,255C,255S Page9

1.3 Shielding Gas Supply (For the Gas Metal Arc Welding Process)

Obtain cylinder of appropriate type shielding gas for theprocessbeingused.

1. Set gas cylinder on rear platform of the machine. Hookchaininplacetosecurecylindertorearofwelder.

2. Remove the cylinder cap. Inspect the cylinder valve fordamaged threads, dirt and dust. For cylinders having anexternal thread fitting, removeanydustanddirt from thethreadswithacleancloth.

DO NOT ATTACH THE REGULATOR/FLOWMETERIF OIL, GREASE OR CYLINDER VALVE DAMAGE ISPRESENT. OIL OR GREASE IN THE PRESENCE OFHIGHPRESSUREOXYGENISEXPLOSIVE!Informyourgassupplierofthiscondition.

3. Stand to one side away from the outlet and open thecylindervalveforaninstant.Thisblowsawayanydustordirtwhichmayhaveaccumulatedinthevalveoutlet.

4. Inspect the regulator/flowmeter for damaged threads andseals,dirtanddust.Removedustanddirtwithacleancloth.

DO NOT USE THE REGULATOR/FLOWMETER IFDAMAGEISPRESENT!Haveanauthorisedrepairstationrepairanydamage.

5. Attach the regulator/flowmeter to the cylinder valve andtightentheunionnut(s)securelywithaspanner.

6. Attach themachines inletgashose to theoutlet fittingoftheregulator/flowmeter,andtightentheunionnutsecurelywithaspanner.

7. Before opening the cylinder valve, turn the regulatoradjustingknobcounter-clockwiseuntiltheadjustingspringpressureisreleased.

8. Openthecylindervalveslowlyafractionofa turn.Whenthe cylinder pressure gauge pointer stops moving, openthevalvefully.

9. The regulator/flowmeter is adjustable. Set it for the flowrate recommended for the procedure and process beingusedbeforestartingtoweld.

1.4 Gun and Cable Installation

LINCGun®240G/360GMIGgun(assupplied) 1. Laythecableoutstraight. 2. Make sure all pins on the gun cable connector are

aligned with the proper mating sockets on the frontpanelgunconnectorandthenjointheconnectorsandtightenthehandnutontheguncableconnector.

Note: If a gun and cable other than the supplied gun isto be used, it must conform to standard European-styleconnectorspecifications.SeePicture.

The gun trigger switchmust be capable of switching 10milliampsat60voltsDC—resistive.

1.5 Output Polarity Connection 215C and 255C only

Theelectrodecableislocatedbetweenoutputterminals.TheelectrodecableisconnectedtotherequiredoutputterminalonthefrontoftheREDI-MIG®Plus215Cand255C.Thegunpolaritycanbechangedbyplacingtheelectrodecabletotherequiredoutputterminal,eg.forelectrode(-)ve,connecttheelectrodecabletothe(-)veoutputstud.Connecttheworkleadtotheotheroutputterminal.

Output Polarity Connection 255SThe PWF4S wire feeder is connected to the REDI-MIG® Plus255S separate power source via a control/electrode/gas cableassembly. The electrode cable is connected to the requiredoutputterminalonthefrontoftheREDI-MIG®Plus255Sseparatepowersource.The control cable connects to the plug on the front of theREDI-MIG®Plus255Sseparatepowersource,betweentheoutputterminals.The gun polarity can be changed by placing the electrodecable to the required output terminal on the front of theREDI-MIG® Plus 255S, eg. for electrode (-)ve,connect the electrode cable to the (-)ve output terminal.Connecttheworkleadtotheotheroutputterminal.

Gas under pressure is explosive. Always keep gascylindersinanuprightpositionandalwayskeepchainedto undercarriage or stationary support. Refer “Safety inWelding and Cutting” - ANSI Standard Z49-1 and WTIATechnicalNote7available from theWeldingTechnologyInstituteofAustralia.

WARNING

Never stand directly in front of or behind the regulator/flowmeterwhenopeningthecylindervalve.Alwaysstandtooneside.

The gun trigger switch connected to the gun triggercontrolcablemustbeanormallyopen,momentaryswitch.The terminals of the switch must be insulated from thewelding circuit. Improper operation of, or damage to,themachinemight result if thisswitch iscommon toanelectricalcircuitotherthanthemachinetriggercircuit.

CAUTION

Turnthewelderpowerswitchoffbeforeinstallinggunandcable.

WARNING

Turn the welder power switch off before changingpolarity.

Referto“SafetyinWeldingandCutting”-ANSIStandardZ49-1 and WTIA Technical Note 7 available from theWeldingTechnologyInstituteofAustralia.Please also refer to “Safety in Welding and Alliedprocesses-AS1674.1&.2”andWTIATechnicalNote7–TN07.AustralianStandardsareavailablefromSAIGlobal–www.saiglobal.comandWTIApublicationsareavailablefrom the Welding Technology Institute of Australia –www.wtia.com.au”.

WARNING

CYLINDER may explode if damaged

Page10 REDI-MIG®Plus215C,255C,255S IM6016

Welding voltage values for REDI-MIG® Plus 215C, 255C, 255S

REDI-MIG®®

Plus 215CREDI-MIG®®

Plus 255CREDI-MIG®®

Plus 255S

Position Volts Volts Volts

1 15.5V 16V 16V

2 16V 16.5V 16.5V

3 17.1V 17.5V 17.5V

4 18.1V 18.6V 18.6V

5 19.1V 19.6V 19.6V

6 20.1V 21.6V 21.6V

7 21.1V 22.2V 22.2V

8 22.3V 23.2V 23.2V

9 23.2V 24.7V 24.7V

10 25V 26.8V 26.8V

11 25.5V 27.8V 27.8V

12 26.1V 29V 29V

1. POWER SWITCH – Turnspoweronandoffwithbuilt-inindicatorlight.

2. OVER TEMPERATURE LIGHT – Indicateswhenexceedingdutycyclei.e.basedon10minutetimeperiodfor60%dutycycle,ifactualweldingtimeexceeds6minutesthelightwillcomeon.Theinputpowerremainsonkeepingthecoolingfanoperative.

3. WIRE FEED SPEED CONTROL (WFS) – Usethiscontroltoadjustthespeedatwhichthewirefeedswhenwelding.Thisisineffectacurrentcontrolasthepowersourcewilldeliverthecurrentnecessarytomeltthewire.Thehigherthespeed,themorecurrentwillberequired.Wirefeedspeedrangeisapproximately1to20m/min.

Operationoftheguntriggerswitchesthewirefeedmotoronandoff.Thewirefeedmotorisdynamicallybrakedtominimisewireoverrunafterweldinghasceased.

4. TORCH CONNECTION – Eurotorchconnection

5. ARC VOLTAGE CONTROL –Theoutputvoltageiscontrolledbyrotaryswitch.ThisislocatedontheseparatewirefeederoftheREDI-MIG255S.Theapproximateweldvoltagesfortherotaryswitchpostionsforthe215C,255Cand255Sareabove.

6. AMPERAGE AND VOLTAGE METER - Digitalmeterdisplaysweldingvoltage.SuppliedasstandardonREDI-MIG®Plus255S.AvailableasafieldfitoptionforotherREDI-MIG®Plusmodels.

WARNING

ELECTRICSHOCKcankill

FUMESANDGASEScanbedangerous

WELDINGSPARKScancausefireor

explosion

•Donottouchelectricallylivepartsorelectrodewithskinorwetclothing.

•Insulateyourselffromworkandground.

•Alwaysweardryinsulatinggloves.

•Keepyourheadoutoffumes.

•Useventilationorexhausttoremovefumesfrombreathingzone.

•Keepflammablematerialaway.

•Donotwelduponcontainerswhichhaveheldcombustibles.

•Weareye,earandbodyprotection.

ARCRAYScanburn

IMPORTANTSAFETYNOTE:In2Tmode{referpoint10below}, this DC Constant Voltage wire welder provides“COLD”electrodewhen thegun trigger isnotoperated.Conversely, the output terminals are “LIVE” when thegun trigger is “activated” when pressed in 2Tmode, ortriggeredonin4Tmode.

Section 2 - OPERATING INSTRUCTIONS

IM6016 REDI-MIG®Plus215C,255C,255S Page11

Section 2 - OPERATING INSTRUCTIONS

7. Spool Gun Connection -Connectionfortheoptionalspoolgunonthe215Cand255C.

8. GAS PURGE/WIRE INCH – AtwopositiontoggleswitchlocatedontheREDI-MIG®Plus4sUsethegaspurgemomentarytoggleswitchtooperatethegassolenoidtopurgeairfromthegassupplyafterconnectinganewgascylinder.Gaspurgewillonlyoperatewhilethetoggleswitchisheldupwards.Usethesametoggleswitchtooperatethewirefeedmotorand“cold”inchthewire,bypushingthetoggleswitchdownwards.

9. 2 STEP/4 STEP TRIGGER OPERATION –AtwopositiontoggleswitchlocatedinsidethewirefeederdooroftheREDI-MIG®215Cand255C.Thisprovidestwomodesofoperationoftheguntrigger.In2stepmode,theguntriggerispressedtostartweldingandreleasedtostop.

Inthe4stepmode,pressingtheguntriggeronlyoperatesthegassolenoid,allowingshieldinggastoflow.Releasingtheguntriggeractivatesthecontactorwhichstartsthewirefeedmotorandconnectsweldingcurrenttothewiresothatweldingmaycommence.Tostopwelding,thetriggermustagainbeoperated;pressingitstopsthewirefeed,activatestheburnbacktimedelayandopensthecontactorafterthepre-setburnbacktime.Releasingthetriggerstopsthegasflow.

Torecommencewelding,theabovecyclemustberepeated.

10. Output Terminals –Dinseconnectionusedtoconnectelectrodecableandworkreturnlead.

FOROUTPOLARITYCONNECTIONREFERTOSECTION1.5

11. CONTROL CABLE OUTPUT CONNECTION - ThecontrolcableconnectstotheoutputconnectionplugonthefrontoftheREDI-MIG®Plus255Spowersourceabovetheoutputterminals.Thecontrolcableisusedtoconnectthewirefeedertothepowersource.

BURNBACK CONTROL –Thiscontrolislocatedinthewirefeedbay.Theburnbackcontroladjuststhetimeperiodfromwhenthedrivemotorstopsuntilthepowersourceandgassolenoidareswitchedoff(approximately0.1secondswhenfullyanti-clockwiseto1.1secondswhenadjustedfullyclockwise).

Thepurposeoftheburnbackcontrolistopreventtheelectrodewirestickingintheweldcrateratthefinishoftheweld.

1

2

5

7 4

3

6

4

3

6

1

2

5

7

1

2

5

4

3

6

11

8

11

10

Please note -9notshown

10 10

Page12 REDI-MIG®Plus215C,255C,255S IM6016

Thefollowingitemsarerequired:1) Areelofwireofsuitablesizeandtype.2) Asuitablegunandcableassemblywitha“Euro”connector

and the correct tip and, if necessary gas nozzle for theconsumablebeingused.(LINCGunMIGgunissupplied).

3) Correctdriverollsforthewiresizeandtypetobeused.TheREDI-MIG®Plus215Cand255Caresuppliedwitha0.8-0.9mmdriveroller.TheREDI-MIG®Plus255Saresuppliedwitha0.9-1.2mmdriveroller.Driverolls forother typesandsizesareavailableasspareparts.(Seetableonpage16).

4) Aworkreturncableandclamp.(Supplied)5) Normal welding accessories including helmet or hand

shieldwithsuitablelens,glovesetc.6) If a gas shielded process is to be used, a cylinder of

appropriateshieldinggasisrequired.(Regulator/flowmeterandhosearesupplied.)Ifgasshieldingisrequired,connectthegashose.

Remember that gas cylinders may explode if damaged, soensurethatallgascylindersaresecurelymounted.Ensurethatthe correct type and sizewire feed rolls are fitted. In replacingwire feed rolls, ensure that the key and keyway are correctlypositionedandtightentheknurledlockingscrewsecurely.

Fit a spool of appropriate wire onto the spool so that it turnsclockwiseasthewireisfed.Carefullyreleasetheendofthewirefromthespoolensuringthatthereleasedendisheldtostopthewirefromunravelling.Cutofftheendkinktogiveasmoothstraightendofwire.Obtain a gap between the wire feed roll and the pressure rollby lifting thecam latch.Feed thewireend into theguide tube,betweenthedriverolls,andintothe“Euro”connectorguideuntilitprotrudesabout20mmoutofthefrontofthe“Euro”connector.Close the drive rolls by lowering the cam latch ensuring therolls firmly hold thewire. Adjust the tension so that wire feedssmoothly.Donotovertighten.Fit the gun and cable assembly onto the “Euro” connector byslippingtheendofwireintothecablewirehole.Tightenthe“Euro”connectorlockring.Activatethepowersource;setthewirefeedspeedto4onthedialandpresstheguntriggerorwireinchpushbutton(iffitted).Thewirefeedrollshouldturn,feedingthewirefurtherupthegunandcableassembly.Ensuretherearenokinksorsharpbendsintheguncableandhold thegun triggerorwire inchbuttonuntil thewireemergesfromthegun.Itisgoodpracticetoremovethetipwhenfirstfeedinganewcoilofwire,thenrefittingoverthewireandtightening.Cutofftheendofthewireleaving10mmto15mmstick-out.Selectrequiredpolarity.SeeSection1.5

Section 3 - SETTING UP FOR WELDING

AC1400

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IM6016 REDI-MIG®Plus215C,255C,255S Page15

REDI-MIG4s–Putinto2TSteptriggermode Selecttheoutputvoltagerequiredtosuitthejobbysetting

therotaryvoltageswitches.(RefertoREDI-MIG®WeldingGuideforsuggestedsettings).

Before beginning welding, ensure the wire protrudesfrom thegun tipbyapproximately10-15mm.Ensuregasis turned on for gas shielded processes.Ensureweldingshieldandotherprotective clothingare inplace.Presenttheprotrudingelectrodejustoffthework.Maintainasteadygripon thegun,protect youreyeswithawelding shield,thenpressandholdtheguntriggertocreatethearc.

If it isnecessary toadjust theweldvoltage,stopweldingbeforechangingtherotaryvoltageswitches.

Adjustthewirefeedspeedasnecessarytosuitthejob.Atthecompletionoftheweld,releasetheguntriggerandholdthegunovertheweldpooltostopthearc.

4TSteptriggermodeshouldonlybeusedfor longweldsbyexperiencedoperators.

4.1 Changing Electrode Size and Type Whenchangingtheelectrodesizeortype,ensurethewire

feeddriverollisthecorrectsizeandtypefortheelectrode.Wire feed drive rolls have two grooves each of differentsizes.Ensuretherollislocatedbythekey.

When changing to aluminium welding a new drive roll,cablelinerandcontacttipshouldbeused.

When changing to cored wire welding, a new drive rollshouldbeused.

Alsocheckelectrodepolarity,asdifferentprocessesmayrequiredifferentpolarities.

Note: Ensure that the correct gun liner and contact tipare used for differentwire sizes and processes.Changegun liner as necessary. See Section 6.5 Liner Removal,InstallationandTrimmingInstructionsforLINCGun®240&360MIGguns.

4.2 Adjusting Spool Tension The spool should stop rotating when the wire feed roll

stops. Overrun of the spool can cause the coil of wireto unravel. The spool hub should be tensioned so thatit neither drags nor overruns. The tension can be set byadjustingthelargenutinsidethehubwithatubespanner.

Section 4 - WELDING

When thegun trigger is pressed (2TmodeonREDI-MIG4s) or pressed and released the first time (4T mode onREDI-MIG 4s), the wire is at welding voltage. The wireshouldnevertouchthecaseofthewirefeeder.Ifitdoes,itispossibleforthewiretoarctothecase.Anywireoverrunshouldbeavoided.

WARNING

MaterialNo. Size(mm) UsedWith ForUseWith KP61015-08 0.6/0.8 Solid Redimig®Plus215/255C KP61015-09 0.8/0.9 Solid Redimig®Plus215/255C KP61015-0912 0.9/1.2 Solid Redimig®Plus215/255C KP61015-0912A 0.9/1.2 Aluminium Redimig®Plus215/255C KP61015-12 1.0/1.2 Solid Redimig®Plus215/255C KP61015-0912R 0.9/1.2 Cored Redimig®Plus215/255C KP61015-16R 1.2/1.6 Cored Redimig®Plus215/255C KP61240-08 0.6/0.8 Solid Redimig®Plus255S KP61240-0912 0.9/1.2 Solid Redimig®Plus255S KP61240-16 1.2/1.6 Solid Redimig®Plus255S KP61240-0912A 0.9/1.2 Aluminium Redimig®Plus255S KP61240-12A 1.0/1.2 Aluminium Redimig®Plus255S KP61240-0912R 0.9/1.2 Cored Redimig®Plus255S KP61240-16R 1.2/1.6 Cored Redimig®Plus255S

AvailableDriveRolls

Section 5 - LEARNING TO WELD Noonecanlearntoweldsimplybyreadingaboutit.Skill

comesonlywithpractice.Thefollowingpageswillhelptheinexperiencedoperatortounderstandweldinganddevelopthisskill.

5.1 The Arc-Welding Circuit Theoperatorsknowledgeofarcweldingmustgobeyond

thearc itself.Theoperatormustknowhowtocontrol thearc, and this requires a knowledge of thewelding circuitandtheequipmentthatprovidestheelectriccurrentusedinthearc.Thecircuitbeginswheretheguncableisattachedto the welding machine. Current flows through the guncable,gun,andcontacttip,tothewireandacrossthearc.Ontheworksideofthearc,currentflowsthroughthebasemetaltotheworkcableandbacktotheweldingmachine.Thiscircuitmustbecompleteforthecurrenttoflow.

Thismachine’sweldingcircuithasavoltageoutputof45voltsDCmaximum.This voltage isquite lowand isonlypresentwhentheguntriggerisdepressed.

Toweld,theworkclampmustbetightlyconnectedtocleanbasemetal.Removepaint,rust,dirtoroilasnecessaryandconnecttheworkclampascloseaspossibletotheareayouwishtoweld.Thishelpspreventcurrentfromgoingthroughanunwantedpath.Avoidallowingtheweldingcircuittopassthroughhinges,bearings,electroniccomponents,orsimilardevicesthatcanbedamaged.Alwaysdisconnectelectricaldevicesbeforeweldinguponthem.

Fumesandslaggeneratedfromelectrodesrecommendedforusewiththisweldingmachinecanbetoxic.• Avoidcontactwitheyesandskin.• Donottakeinternally.• Keepoutofreachofchildren.• Followallsafetyprecautionsfoundinthisoperating

manual. The gun and cable assembly is held by the operator

who guides the automatically fed wire along the joint,maintainingacontacttiptoworkdistanceofabout10-12mmThisiscalledelectricalstickout.Thiselectricalstickout(ESO)mustbeproperlymaintainedby theoperator.Theelectricarcismadeinthegapbetweentheworkandthetipendofasmalldiameterwire.Whenthepowersourceisproperlyset,thearcgapismaintainedautomatically.

Arc welding is a manual skill requiring a steady hand,goodphysicalcondition,andgoodeyesight.Theoperatorcontrolstheweldingarc,and,therefore,thequalityoftheweldmade.

FUMES AND GASES can be dangerous

Page16 REDI-MIG®Plus215C,255C,255S IM6016

5.2 The Self-Shielded (Gasless) FCAW Welding Arc (DC-)

Figure 1 illustrates the action taking place in the selfshieldedgaslessFCAWweldingarc. Itcloselyresembleswhatisactuallyseenwhilewelding.

The“arcstream”isseeninthemiddleofthepicture.Thisis the electric arc created by the electric current flowingthrough thespacebetween theendof thewireelectrodeand thebasemetal.The temperatureof thisarc isabout3300°C,whichismorethanenoughtomeltmetal.

Thearcisverybright,aswellashot,andcannotbelookedat with the naked eye without risking painful injury. Theverydark lens,specificallydesignedforarcweldingmustbeusedwiththehandorfaceshieldwheneverviewingthearc.

Thearcmeltsthebasemetalandactuallydigsintoitmuchaswaterthroughanozzleonagardenhosedigsintotheearth.Themoltenmetalformsamoltenpoolorcraterandtendstoflowawayfromthearc.Asitmovesawayfromthearc,itcoolsandsolidifies.

The function of the cored wire electrode is much morethan simply to carry current to the arc. Thewire core iscomposed of fluxes and/or alloying ingredients aroundwhichasteelsheathhasbeenformed.Itissimplyastickelectrode turned inside out in a continuous wire form.

Thecoredwiremeltsinthearcandtinydropletsofmoltenmetalshootacrossthearcintothemoltenpool.Thewiresheathprovidesadditionalfillermetalforthejointtofillthegrooveorgapbetweenthetwopiecesofbasemetal.

Thecorematerialsalsomeltorburninthearcandperformseveral functions.Theymake thearc steadier, provideashield of smoke-like gas around the arc to keep oxygenand nitrogen in the air away from themoltenmetal, andprovide a flux for the molten pool. The flux picks upimpuritiesandformstheprotectiveslagontopoftheweldduringcooling.

After running a weld bead, the slag may be removedwith a chipping hammer and wire brush. This improvesappearanceandallowsforinspectionofthefinishedweld.

Machinesizeandoutputcharacteristics limit thesizeandtypeofwireelectrodewhichcanbeused.

5.3 The GMAW (MIG) Welding Arc (DC+) Figure 2 illustrates the GMAW (MIG) welding arc. Solid

wiredoesnotcontainfluxesoringredientstoformitsownshieldingandnoslagformstoprotectthemoltenweldmetal.Forthisreason,acontinuousevenflowofshieldinggasisneededtoprotectthemoltenweldmetalfromatmosphericcontaminantssuchasoxygenandnitrogen.Shieldinggasis supplied through thegunand cableassembly, throughthegasnozzleandintotheweldingzone.

When comparing theGMAWandFCAWprocesses, youcanseethattheprincipaldifferencebetweenthetwoliesinthetypeofshieldingused.GMAWusesgasforshielding,thus we have Gas Metal Arc Welding. FCAW uses themeltingorburningofthecoreingredientsforshielding,andisthustermedSelf-ShieldedFluxCoredArcWelding.

Gas Metal Arc Welding (MIG) is capable of welding awide rangeofmild steels in all positions, however,moreskillisrequiredforout-of-positionweldingwiththeGMAWprocess.

5.4 Process Selection Bygainingknowledgeofthedifferencesbetweenthetwo

processes, you will be able to select the best processfor the jobyouhaveathand. Inselectingaprocess,youshouldconsider:

ForGMAW(MIG)Process 1. Can I afford the extra expense, space, and lack of

portabilityrequiredforgascylindersandgassupply? 2. DoIrequireclean,finished-lookingwelds? If you have answered yes to all the above questions

GMAWmaybetheprocessforyou.Ifyouhaveanswerednotoanyoftheabovequestions,thenyoushouldconsiderusingtheFCAWprocess.

ForFCAW(Innershield)Process 1. DoIwantsimplicityandportability? 2. Will welding be performed outdoors or under windy

conditions? 3. DoIrequiregoodallpositionweldingcapability?

5.5 Common Metals Mostmetals foundaround the farm,small shoporhome

are low carbon steel, sometimes referred to as mildsteel. Typical itemsmade with this type of steel includemost sheetmetal, plate, pipe and rolled shapes suchaschannels and angle irons. This type of steel can usuallybeeasilyweldedwithoutspecialprecautions.Somesteels,however,containhighercarbonlevelsorotheralloysandare more difficult to weld. Basically, if a magnet sticksto themetalandyoucaneasilycut themetalwitha file,chancesaregoodthatthemetalismildsteelandthatyouwill be able to weld the material. In addition, aluminumandstainlesssteelcanbeweldedusingtheanaluminumwelding kit. For further information on identifying varioustypesofsteelsandothermetals,andforproperproceduresforweldingthem,wesuggestyoupurchaseacopyof“NewLessonsinArcWelding”.

Regardlessofthetypeofmetalbeingwelded, inordertogetaqualityweld,itisimportantthatthemetalisfreeofoil,paint,rustorothercontaminants.

5.6 Machine Set up for the Self-Shielded (Gasless) FCAW Process

1. Ensurethemachinehasthecorrectdriverollandparts.2. See theWelding Procedure Guide on the inside of wire

feedsectiondoorforinformationonsettingthecontrols.3. Setthe“Voltage”and“WireSpeed”controlstothesettings

suggestedontheWeldingProcedureGuidefortheweldingwireandbasemetalthicknessbeingused.

4. Check that the polarity is correct for the welding wirebeingused.SeeSection1.5 for instructionsonchangingpolarity.

5. Connectwork clamp tometal to bewelded.Work clampmust make good electrical contact to the work piece.Thework piecemust also be grounded as stated in the“ArcWeldingSafetyPrecautions”at thebeginningof thismanual.

Burningofcorematerialsinside wire electroderesultsinshieldofgas.

ArcStream

CoredWire

ProtectiveSlag

WeldMetal

Figure1

Gasnozzle

ShieldinggasSolidwireelectrode

Figure2

IM6016 REDI-MIG®Plus215C,255C,255S Page17

5.7 Welding Techniques For The Self-Shielded (Gasless) FCAW Process

Foursimplemanipulationsareofprime importancewhenwelding.Withcompletemasteryofthefour,weldingwillbeeasy.Theyareasfollows:

1. TheCorrectWeldingPosition Figure 3 illustrates the correct welding position for

righthandedpeople. (For lefthandedpeople, it is theopposite.)

Hold thegun(of thegunandcableassembly) inyourrighthandandholdtheshieldwithyourlefthand.(Lefthanderssimplydotheopposite.)

WhenusingtheFCAWProcess,weldfromlefttoright(if you are right handed). This enables you to clearlyseewhatyouaredoing.(Lefthandersdotheopposite.)Tilt the gun toward the direction of travel holding theelectrodeatanangleasshowninFigure3.

When using an open arc process, it is necessary to usecorrecteye,headandbodyprotection.Protectyourselfandothers,read“ARCRAYScanburn”atthefrontofthismanual. 2. TheCorrectWayToStrikeAnArc 1. Be sure the work clamp makes good electrical

contacttothework. 2. Position gun over joint. End ofwiremay be lightly

touchingthework. 3. Positionfaceshieldtoprotectfaceandeyes,close

guntrigger,andbeginwelding.Holdthegunsothatthe contact tip to work distance is about 10 - 12mm.

4. Tostopwelding,releasetheguntriggerandpullthegunawayfromtheworkafterthearcgoesout.

5. Aballmayformatthetipendofthewireafterwelding.For easier restrikes the ball may be removed byfeedingoutafewinchesofwireandsimplybendingthewirebackandforthuntilitbreaksoff.

6. When nomorewelding is to be done, turn off themachine.

3. TheCorrectElectricalStickout(ESO) The electrical stickout (ESO) is the distance from the

endofthecontacttiptotheendofthewire. SeeFigure4. Once the arc has been established, maintaining the

correct ESO becomes extremely important. The ESOshouldbeapproximately10-12mmlong.

The easiest way to tell whether the ESO is the correct lengthis by listening to its sound. The correct ESO has a distinctive“crackling” sound, verymuch like eggs frying in a pan. A longESOhasahollow,blowingorhissingsound. If theESO is tooshort,youmaystickthecontacttipornozzletotheweldpuddleand/orfusethewiretothecontacttip. 4. TheCorrectWeldingSpeed Theimportantthingtowatchwhileweldingisthepuddle

ofmoltenmetalrightbehindthearc.SeeFigure5.Donot watch the arc itself. It is the appearance of thepuddleandtheridgewherethemoltenpuddlesolidifiesthat indicatescorrectweldingspeed.Theridgeshouldbeapproximately10mmbehindthewireelectrode.

Mostbeginnerstendtoweldtoofast,resultinginathinuneven, “wormy” lookingbead.Theyarenotwatchingthemoltenmetal.

HelpfulHints 1. For generalwelding, it is not necessary toweave the

arc, neither forward or backward nor sideways.Weldalongatasteadypace.Youwillfinditeasier.

2. Whenweldingon thinplate, youwill find that youwillhave to increase the welding speed, whereas whenwelding on heavy plate, it is necessary to go moreslowlyinordertogetgoodpenetration.

3. When welding sheet metal 1.6 mm and lighter, heatbuildup may cause part warpage and burn through.One way to eliminate these problems is to use theback-steppingmethodillustratedinFigure6.

Practice The best way of getting practice in the four skills that

enableyoutomaintain: 1. Correctweldingposition 2. Correctwaytostrikeanarc 3. Correctelectricalstickout 4. Correct welding speed is to perform the following

exercise.

Figure3

ARC RAYS can burn eyes and skin

10-12mmElectricalStickout(ESO)

ContactTip

WireElectrode

Figure4

SolidifyingridgeMoltenpuddle

Figure5

FirstweldfromAtoB;thenfromCtoA;thenfromDtoC;thenfromEtoD,andsoon.

B A C D E

Back-Stepping

Figure6

Page18 REDI-MIG®Plus215C,255C,255S IM6016

RefertoFigure7.1. Learntostrikeanarcbypositioningthegunoverthejoint

andtouchingthewiretothework.2. Positionfaceshieldtoprotectfaceandeyes.3. Depress gun trigger, hold gun so contact tip to work

distance is about 10 to 12mmand the gun is at properangle.

4. After you strike the arc, practice the correct electricalstickout.Learntodistinguishitbyitssound.

5. Whenyouaresurethatyoucanholdthecorrectelectricalstickout,withasmooth“crackling”arcstartmoving.Lookatthemoltenpuddleconstantly,andlookatthe“ridge”wherethemetalsolidifies.

6. Run beads on a flat plate. Run them parallel to the topedge (the edge farthest away from you). This gives youpractice in running straight welds, and also gives youan easyway to check your progress. The 10thweldwilllookconsiderablybetter thanthefirstweld.Byconstantlycheckingonyourmistakesandyourprogress,weldingwillsoonbeamatterofroutine.

5.8 Machine Set Up for the GMAW (MIG) Process and Gas Shielded GCAW Processes

1. TheREDI-MIG®Plus comes ready forwelding using theMIGprocess.

2. See the ProcedureWelding Guide on the inside of wirefeedsectiondoorforinformationonsettingthecontrols.

3. Setthe“Voltage”and“WireSpeed”controlstothesettingssuggestedontheProcedureWeldingGuidefortheweldingwireandbasemetalthicknessbeingused.’

4. Checkthatthepolarityiscorrectfortheweldingwirebeingused. Set the polarity for DC(+) when welding with theGMAW(MIG)process.SeeSection1.5forinstructionsforchangingpolarity.

5. Checkthatthegasnozzleandpropersizelinerandcontacttiparebeingusedandthatthegassupplyisturnedon.Setfor7to10L/min.undernormalconditions,increasetoashighas17L/min.underdrafty(slightlywindy)conditions.

6. Connectwork clamp tometal to bewelded.Work clampmust make good electrical contact to the work piece.Thework piecemust also be grounded as stated in the“ArcWeldingSafetyPrecautions”at thebeginningof thismanual.

5.9 Welding Techniques for the GMAW (MIG) Process

Foursimplemanipulationsareofprime importancewhenwelding.Withcompletemasteryofthefour,weldingwillbeeasy.Theyareasfollows:

1. TheCorrectWeldingPosition Figure 8 illustrates the correct welding position for

righthandedpeople. (For lefthandedpeople, it is theopposite.)

When GMAW (MIG) welding on sheet metal, it isimportanttousethe“forehand”pushtechnique.

Hold thegun(of thegunandcableassembly) inyourrighthandandholdtheshieldwithyourlefthand.(Lefthanderssimplydotheopposite.)Weldfromrighttoleft(ifyouarerighthanded).Thisresults inacolderweldandhaslesstendencyforburnthrough.

When using an open arc process, it Is necessary to usecorrecteye,headandbodyprotection.Protectyourselfandothers,read“ARCRAYScanburn”atthefrontofthismanual. 2. TheCorrectWayToStrikeAnArc 1. Be sure the work clamp makes good electrical

contacttothework. 2. Position gun over joint. End ofwiremay be lightly

touchingthework. 3. Positionfaceshieldtoprotectfaceandeyes,close

guntrigger,andbeginwelding.Holdthegunsothatthe contact tip to work distance is about 10 - 12mm.

4. Tostopwelding,releasetheguntriggerandpullthegunawayfromtheworkafterthearcgoesout.

5. A ball may form at the tip end of the wire afterwelding. For easier restrikes, the ball may beremoved by feeding out a few inches of wire andcuttingofftheendofthewirewithwirecutters.

6. When no more welding is to be done, close thevalveon thegascylinder,momentarilyoperate theguntriggertoreleasegaspressure,thenturnoffthemachine.

Figure7

MildSteelPlate 4.0mm WireSizeandtype 0.9mm Innershield211MP VoltageSetting 6 WireFeedSpeed 3.5

FortheREDI-MIG®Plus255Cusethefollowing:

Figure8

ARC RAYS can burn eyes and skin

Figure9

IM6016 REDI-MIG®Plus215C,255C,255S Page19

3. TheCorrectElectricalStickout(ESO) The electrical stickout (ESO) is the distance from the

endofthecontacttiptotheendofthewire.SeeFigure9.

Once the arc has been established, maintaining thecorrect ESO becomes extremely important. The ESOshouldbeapproximately10to12mmlong.

TheeasiestwaytotellwhethertheESOisthecorrectlengthisbylisteningtoitssound.ThecorrectESOhasa distinctive “crackling” sound, very much like eggsfrying in a pan.A longESOhasahollow, blowingorhissingsound.IftheESOistooshort,youmaystickthecontacttipornozzletotheweldpuddleand/orfusethewiretothecontacttip.

4. TheCorrectWeldingSpeed Theimportantthingtowatchwhileweldingisthepuddle

of molten metal right behind the arc. See Figure 10.Donotwatchthearcitself.It istheappearanceofthepuddleandtheridgewherethemoltenpuddlesolidifiesthat indicatescorrectweldingspeed.Theridgeshouldbeapproximately10mmbehindthewireelectrode.

Mostbeginnerstendtoweldtoofast,resultinginathin,uneven, “wormy” lookingbead.Theyarenotwatchingthemoltenmetal.

HelpfulHints

1. For generalwelding, it is not necessary toweave thearc, neither forward or backward nor sideways.Weldalongatasteadypace.Youwillfinditeasier.

2. Whenweldingon thinplate, youwill find that youwillhave to increase the welding speed, whereas whenwelding on heavy plate, it is necessary to go moreslowlyinordertogetgoodpenetration.

3. When welding sheet metal 1.6mm and lighter, heatbuildup may cause part warpage and burn through.One way to eliminate these problems is to use theback-steppingmethodillustratedinFigure6.

Practice The best way of getting practice in the four skills that

enableyoutomaintain: 1. Correctweldingposition 2. Correctwaytostrikeanarc 3. Correctelectricalstickout 4. Correctweldingspeed istoperformthefollowingexercise. RefertoFigure4. RefertoFigure7.

1. Learn tostrikeanarcbypositioning thegunover thejointandtouchingthewiretothework.

2. Positionfaceshieldtoprotectfaceandeyes. 3. Depress gun trigger, hold gun so contact tip to work

distance Is about 10-12 mm and the gun is at properangle.

4. After you strike the arc, practice the correct electricalstickout.Learntodistinguishitbyitssound.

5. Whenyouaresurethatyoucanholdthecorrectelectricalstickout,withasmooth“crackling”arc,startmoving.Lookatthemoltenpuddleconstantly,

6. Run beads on a flat plate. Run them parallel to the topedge (the edge farthest away from you). This gives youpractice in running straight welds, and also gives youan easyway to check your progress. The 10thweldwilllookconsiderablybetter thanthefirstweld.Byconstantlycheckingonyourmistakesandyourprogress,weldingwillsoonbeamatterofroutine.

5.10 Joint Types and Positions Fivetypesofwelding jointsare:ButtWelds,FilletWelds,

LapWelds,EdgeWeldsandCornerWelds.SeeFigure10.

Of these, theButtWeldandFilletWeldarethetwomostcommonwelds.

5.11 Butt Welds Placetwoplatessidebyside,leavingaspaceapproximately

onehalfthethicknessofthemetalbetweentheminordertogetdeeperpenetration.

Securely clamp or tack weld the plates at both ends,otherwisetheheatwillcausetheplatestomoveapart.SeeFigure11.

Nowweld the twoplates together.Weld from left to right(if right handed and using self-shielded FCAW process).Pointthewireelectrodedowninthecrackbetweenthetwoplates,keepingthegunslightlytiltedinthedirectionoftravel.

Watchthemoltenmetaltobesureitdistributesitselfevenlyonbothedgesandinbetweentheplates.

5.12 Penetration Unlessabuttweldpenetratescloseto100%ofthemetal

thickness, a butt weld will be weaker than the materialwelded together. In theexampleshown inFigure12, thetotalweldisonlyhalfthethicknessofthematerialthustheweldisonlyapproximatelyhalfasstrongasthemetal.

In the example shown in Figure 13, the joint has beenweldedsothat100%penetrationcouldbeachieved.Theweld,ifproperlymade,isasstrongasorstrongerthantheoriginalmetal.

Figure10

MildSteelSheet (1.6mm) Wiresizeandtype 0.9mmUltramagS6 Argon/CO2Blend VoltageSetting 4 WireFeedSpeed 3

FortheREDI-MIG®Plus255C,usethefollowing:

Buttweld Lapweld

Edgeweld Filletweld Cornerweld

Figure10

Figure12

Figure11

Page20 REDI-MIG®Plus215C,255C,255S IM6016

5.13 Fillet Welds Whenwelding filletwelds, it isvery important tohold the

wireelectrodeata45°anglebetweenthetwosidesorthemetal will not distribute itself evenly. The gun nozzle isgenerallyformedatanangletofacilitatethis.SeeFigure14.

5.14 Welding In The Vertical Position Welding in the vertical position can be done either

vertical-uporvertical-down.Vertical-up isusedwhenevera larger, stronger weld is desired. Vertical-down is usedprimarily on sheet metal 4.0mm and under for fast, lowpenetratingwelds.

5.15 Vertical-up And Overhead Welding Theproblem,whenweldingvertical-up,istoputthemolten

metalwhereitiswantedandmakeitstaythere.Iftoomuchmolten metal is deposited, gravity will pull it downwardsandmakeit“drip”.Therefore,acertaintechniquehastobefollowed.

When welding out-of-position, run stringer beads. Don’twhip,breakthearc,moveoutofthepuddle,ormovetoofast inanydirection.UseWireFeedSpeed(WFS) in thelowportionoftherange.ThegeneraltechniqueandpropergunangleareillustratedinFigure15.

Generally,keep theelectrodenearlyperpendicular to thejointasillustrated.Themaximumangleaboveperpendicularmayberequiredifporositybecomesaproblem.

5.16 Vertical-down Welding RefertoFigure16Vertical-downweldsareappliedatafast

pace.Theseweldsarethereforeshallowandnarrowand,assuch,areexcellentforsheetmetal.Vertical-downweldsmaybeappliedto4.0mmandlightermaterial.

Usestringerbeadsandtiptheguninthedirectionoftravelso thearc forcehelpshold themoltenmetal in the joint.Move as fast as possible consistent with desired beadshape.

Theimportantthingistocontinueloweringtheentirearmas the weld is made so the angle of the gun does notchange.Movetheelectrodewirefastenoughthattheslagdoesnotcatchupwiththearc.Vertical-downweldinggivesthin,shallowwelds.Itshouldnotbeusedonheavymaterialwherelargeweldsarerequired.

5.17 Troubleshooting Welds

Goodweldshaveexcellentappearance.

ToEliminatePorosity(inorderofimportance): 1. Turnongassupply,ifused 2. Decreasevoltage. 3. Increasestickout. 4. IncreaseWFS(wirefeedspeed). 5. Decreasetorchangle. 6. Decreasetravelspeed. Note:Alwaysbe sure the joint is free frommoisture, oil,

rust,paintorothercontaminants. ToEliminateaRopyConvexBead (inorderofimportance): 1. Increasevoltage 2. Decreasestickout. 3. DecreaseWFS(wirefeedspeed). 4. Decreasetravelspeed. 5. Decreasetorchangle. 6. Checkforcorrectgas,ifused

Figure13

45°

Figure14

Use of this unit on thickermaterials than recommendedmayresultinpoorwelds.Theweldsmay“look”good,butmay just be “sitting” on top, of the plate. This is called“ColdLapping”andwillresultinweldfailure.

WARNING

PROPER GUN ANGLE�FOR GMAW PROCESS�WELDING IN THE VERTICAL UP POSITION

PROPER GUN ANGLE�FOR FCAW PROCESS�WELDING IN THE VERTICAL UP POSITION

PropergunangleforFCAWprocessweldingintheverticalupposition.

PropergunangleforGMAWprocessweldingintheverticalupposition.

Figure16

Figure15

IM6016 REDI-MIG®Plus215C,255C,255S Page21

ToReduceSpatter(inorderofimportance):

1. Increasevoltage. 2. Increasetorchangle. 3. Decreasestickout. 4. IncreaseWFS(wirefeedspeed). 5. Decreasetravelspeed. 6. Checkforcorrectgas,ifused. ToCorrectPoorPenetration(inorderofimportance): 1. Decreasestickout. 2. IncreaseWFS(wirefeedspeed). 3. Increasevoltage. 4. Decreasespeed. 5. Decreasetorchangle. 6. Checkforcorrectgas,ifused. IfArcBlowOccurs(inorderofimportance): Note: Try different ground connection locations before

adjustingprocedures.

1. Decreasetorchangle. 2. Increasestickout. 3. Decreasevoltage. 4. DecreaseWFS(wirefeedspeed. 5. Decreasetravelspeed. ToEliminateStubbing*(inorderofimportance): 1. Increasevoltage 2. DecreaseWFS(wirefeedspeed) 3. Decreasestickout 4. Increasetorchangle * Stubbingoccurswhentheelectrodedrivesthroughthe

moltenpuddleandhitsthebottomplatetendingtopushthegunup.

ProperGunHandling Mostfeedingproblemsarecausedbyimproperhandlingof

theguncableorelectrodes. 1. Donotkinkorpullthegunaroundsharpcorners 2. Keep the gun cable as straight as practical when

welding. 3. Do not allow dolly wheels or trucks to run over the

cables. 4. Keepthecableclean. 5. Useonlyclean, rust-freeelectrode.Lincolnelectrodes

havepropersurfacelubrication. 6. Replacecontacttipwhenitbecomeswornortheendis

fusedordeformed.

6.1 Routine Maintenance General Inextremelydustylocations,dirtmayclogtheairpassages

andcausetheweldertorunhot.Blowdirtoutofthewelderwith low-pressure air at regular intervals to eliminateexcessivedirtanddustbuild-uponinternalparts.

The fanmotorhassealedballbearingswhich requirenoservice.

WeldingThermalOverloadProtection The REDI-MIG® Plus and Powerplus units have built-in

protective thermostats that respond to excessivetemperature.Theyopen thewire feedandwelderoutputcircuitsifthemachineexceedsthemaximumsafeoperatingtemperature because of a frequent overload, or highambienttemperatureplusoverload.Theovertemperaturelighton thecontrol panelglows if thermostatsopen.Thethermostats automatically reset when the temperaturereachesasafeoperatinglevel.Thefanwillstayonwhenthe machines welding and feeding are disabled duringthermostaticovertemperatureprotection.

6.2 Gun and Cable Maintenance CableCleaning Clean cable liner after using approximately 150kg of

electrode.Removethecablefromthewirefeederandlayit out straight on the floor. Remove the contact tip fromthe gun.Using an air hose andapprox. 350 kPa (50psi)pressure, gently blow out the cable liner from the gasdiffuserend.

Flexthecableoveritsentirelengthandagainblowoutthecable.Repeatthisprocedureuntilnofurtherdirtcomesout.

6.3 Gun Tips and Nozzles Theguntipshouldbereplacedwhenworn.Replacewith

thecorrectsizeforthewiretypeanddiameter.Toolargeatipfortheelectrodewirewillcausearcingwithintheguncableandpossiblejammingofthewirewithinthecable.

Removespatterfrominsideofgasnozzleandfromtipaftereach10minutesofarctimeorasrequired.

DriveRollsandGuideTubes Aftereverycoilofwire,inspectthewiredrivemechanism.

Clean it as necessary by blowing with low pressurecompressedair.Donotusesolventsforcleaningthe idlerollbecausethismaywashthelubricantoutofthebearing.Alldriverollsarestampedwiththewiresizestheywillfeed.Ifawiresizeother than thatstampedon theroll is tobeused,thedriverollmustbechanged.

AvoidingWireFeedingProblems Wire feeding problems can be avoided by observing the

followinggunhandlingprocedures:- 1. Donotkinkorpullguncablearoundsharpcorners. 2. Keep the gun cable as straight as possible when

weldingorfeedingelectrodethroughcable. 3. Keep gun cable clean by following maintenance

instructions. 4. Use only clean, rust-free electrode. Lincoln Electric

electrodehaspropersurfacelubrication. 5. Replace contact tip when the arc starts to become

unstableorthecontacttipendisfusedordeformed.

6.4 Input Lead If thesupplycord isdamaged, itmustbereplacedwitha

specialcord.Refersparepartlist.

Excessivepressureat thestartmaycausedirt to formaplug.

CAUTION

WARNING

ELECTRICSHOCKcankill

•Haveanelectricianinstallandservicethisequipment.

•Turntheinputpoweroffatthefusebox,orunpluginputleadbeforeworkingonequipment.

•Do not touch electrically hotparts.

Section 6 - MAINTENANCE

Page22 REDI-MIG®Plus215C,255C,255S IM6016

Section 7 - ACCESSORIES

° DriveRollsformildsteel,stainlesssteelandaluminiumforsolidwiresaswellasforfluxcoredwires.SeeyournearestLincolndistributorfordetails.

Changing Settings for Motor AccelerationIf Motor Acceleration needs to be altered from factory setting,because of thewelding procedure being used, locate thePCBintheREDI-MIG®325corREDI-MIG®4sRemoteWireFeeder.

On the PCB there is a trimmer labelled ‘Rampa’, this trimmercontrols theacceleration rateof thedrivemotor fromstationaryto the set wire feed speed. Maximum acceleration when fullycounter-clockwisetominimumaccelerationwhenfullyclockwise.This isparticularly importantwhenweldingaluminiumwire.Thefactorysettingisfullyclockwise.

Procedure for Replacing PC BoardsBefore replacing a PC board suspected of being defective,visuallyinspectthePCboardinquestionforanyvisibledamagetoanyofitscomponentsandconductorsonthebackoftheboard.1. IfthereisnovisibledamagetothePCboard,installanew

oneandsee if this remedies theproblem. If theproblemis remedied, reinstall the original PC board to see if theproblemstillexists.IftheproblemnolongerexistswiththeoldPCboard:

a. Check the PC board harness connector pins forcorrosion,contamination,orlooseness.

b. Checkleadsintheplugharnessforlooseorintermittentconnection.

2. IfPCboardisvisiblydamaged,beforepossiblysubjectingthenewPCboardtothesamecauseoffailure,checkforpossibleshorts,opensorgroundscausedby:

a. Damagedleadinsulation. b. Poorleadtermination,suchasapoorcontactorashort

toadjacentconnectionorsurface. c. Shortedoropenmotorleads,orotherexternalleads. d. ForeignmatterorinterferencebehindthePCboard.3. If PC board is visibly damaged, inspect for cause, then

remedybeforeinstallingareplacementPCboard.

6.5 Liner Removal, Installation and Trimming Instructions for LINC Gun® 240 & 360 Torch

Note: The variation in cable lengths prevents the inter-changeability of liners between guns. Once a liner hasbeen cut for a particular gun, it should not be installedin another gun unless it canmeet the liner cutoff lengthrequirement.

1. Removethegasnozzleandgasdiffuser,(ifused),tolocatethesetscrewinthegasdiffuserwhichisusedtoholdtheoldlinerinplace.LoosenthesetscrewwithanAllenkey.

2. Removethecontacttipholderfromtheguntube.3. Laythegunandcableoutstraightonaflatsurface.Loosen

the liner nut cap located in the brass connector at thefeederendofthecableandpullthelineroutofthecable.

4. Insertanewuntrimmedlinerintotheconnectorendofthecable.

5. Fully seat the liner bushing into the Euro connector.Tightenthelinernutcaponthebrasscableconnector.Thecontacttipholder,atthistime,shouldnotbeinstalledontotheendoftheguntube.

6. Withthecontacttipholderstillremovedfromtheguntube,be sure the cable is straight, and then trim the liner tolength.Removeanyburrsfromtheendoftheliner.

7. Screwthecontacttipholderontotheendoftheguntubeand securely tighten. Be sure the contact tip holder iscorrectforthetipsbeingused.

8. TightenthesetscrewinthesideofthegasdiffuseragainstthecablelinerusinganAllenkey.Donotovertighten.

Note:Thisprocedureisfor‘machinesasbuilt’manymodificationscouldhavetakenplaceover the lifeofaparticularmachine,sodetailsofthisproceduremayneedtobe‘adjusted’tosuitthesemodifications.ForpromptservicecontactyourlocalLincolnFieldServiceShop.TheinsulationresistancevalueslistedbelowarefromAustralianStandardAS60974-.1.1) Disconnectinputcablefrompoweroutlet.2) Disconnectalloutputcables(control&weld).3) Removetheroofpanel.4) Jumper the three (3) AC terminals and the (+) & (-)

terminalsofthethreephasebridgerectifier(Atotaloffive(5)places).

5) Jumperthefour(4)meterterminalstogether.6) Switchthefinecontrolrotaryswitchtoposition‘1’&switch

thecoarsecontrolrotaryswitchtoposition‘1’.7) Primarytest:Connectoneleadofthemegatestertothe

frame of themachine and the other lead to each of thethree (3) input conductors and to the main transformerprimaryleadsL1A,L2A&L3A.Applythetest(s).

8) Welding circuit test: Connect one lead of the megatester to the frameof themachineand theother lead tothe positive output stud. Apply the test. (Min resistance5.0MΩ).

9) Weldingcircuittoprimarytest:Connectoneleadofthemegatestertothepositiveoutputstudandtheotherleadtoeachof thethree(3) inputconductorsandtothemaintransformerprimaryleadsL1A,L2A&L3A.Applythetest.(Minresistance2.5MΩ).

10) Transformer thermostat test: Connect one lead of themegatestertotheframeofthemachineandtheotherleadto thepositiveoutputstud.Apply the test.(Minresistance1MΩ).

11) Removealljumperleads.12) Refittheroofpanel.

WARNING

ELECTRIC SHOCK can kill

This procedure is only suitable for applications using DCmegatestersupto500V.

Section 8 - GROUND TEST PROCEDUREThese procedures refer to the REDI-MIG® 250s, 325c & 325s

IM6016 REDI-MIG®Plus215C,255C,255S Page23

Section 8 - GROUND TEST PROCEDUREThe following procedures refer to the REDI-MIG® 210c & 250c

Procedure for Replacing PC BoardsBefore replacing a PC board suspected of being defective,visuallyinspectthePCboardinquestionforanyvisibledamagetoanyofitscomponentsandconductorsonthebackoftheboard.1. IfthereisnovisibledamagetothePCboard,installanew

oneandsee if this remedies theproblem. If theproblemis remedied, reinstall the original PC board to see if theproblemstillexists.IftheproblemnolongerexistswiththeoldPCboard:

a. Check the PC board harness connector pins forcorrosion,contamination,orlooseness.

b. Check leads in the machine harness for loose orintermittentconnection.

2. IfPCboardisvisiblydamaged,beforepossiblysubjectingthenewPCboardtothesamecauseoffailure,checkforpossibleshorts,opensorgroundscausedby:

a. Damagedleadinsulation. b. Poorleadtermination,suchasapoorcontactorashort

toadjacentconnectionorsurface. c. Shortedoropenmotorleads,orotherexternalleads. d. ForeignmatterorinterferencebehindthePCboard.3. IfPCboardisvisiblydamaged,inspectforcause,thenremedybeforeinstallingareplacementPCboard.

Note:Thisprocedureisfor‘machinesasbuilt’manymodificationscouldhavetakenplaceover the lifeofaparticularmachine,sodetailsofthisproceduremayneedtobe‘adjusted’tosuitthesemodifications.ForpromptservicecontactyourlocalauthorisedLincolnElectricFieldServiceShop.TheinsulationresistancevalueslistedbelowarefromAustralianStandardAS60974.1.1) Disconnectinputcablefrompowersupply.2) Disconnectgunassemblyandworkcable.3) Removethesidepanelfrompowersource.4) Jumperthetwo(2)ACterminalsandbothoutputterminals

ofthebridgerectifier,(atotalofthree(4)places).

5) DisconnectthePCBplug.6) Switch the control rotary switch to position ‘one’ (1) and

switchtheon/offswitchtoon.7) Primary Test: Connect one lead of the mega tester to

theframeofthemachineandtheotherleadtotheActiveterminaloftheinputplug.Applythetest.(Min.resistance2.5MΩ)

8) Weldingcircuittest:Connectoneleadofthemegatestertotheframeofthemachineandtheotherleadtothe(+)veoutputstud.Applythetest.(Min.resistance2.5MΩ)

9) Weldingcircuittoprimarytest:Connectoneleadofthemegatestertothe(+)veoutputstudandtheotherleadtotheActiveterminalof theinputplug.Applythetest.(Min.resistance5MΩ)

10) Transformer thermostat test: Connect one lead of themega to the frameof themachineand theother lead tothe rectifier thermostat terminals. Apply the test. (Min.resistance2.5MΩ)

11) Removealljumpersandreconnectallleadsandplugs.12) Refitallpanelworkpreviouslyremoved.

WARNING

ELECTRIC SHOCK can kill

This procedure is only suitable for applications using DCmegatestersupto500V.

Page24 REDI-MIG®Plus215C,255C,255S IM6016

Problem

Roughwirefeedingorwirenotfeedingbutdriverollsturning.

Variableor“hunting”arc.

Poorarcstrikingwithstickingor“blastoffs”,weldporosity,narrowandropeylookingbead,orelectrodestubbingintoplatewhilewelding.

Tipseizesindiffuser.

PossibleCause

Guncablekinkedand/ortwisted.

Wirejammedingunandcable.

Incorrectlyfitteddriveroll.

Driverollloose.

Guncabledirty.

Worndriveroll.

Electroderustyand/ordirty.

Wornnozzleorcableliner.

Partiallyflashedormeltedcontacttip.

Incorrectidlerollpressure.

Wrongsize,wornand/ormeltedcontacttip.

Wornworkcableorpoorworkconnection.

Looseelectrodeconnections.

Wrongpolarity.

Improperproceduresortechniques.

Impropergasshielding

Tipoverheatingduetoprolongedorexces-sivehighcurrentand/ordutycyclewelding.

WhatToDo

Inspectguncableandreplaceifnecessary.

Removewirefromgunandcable-feedinnewwire.Noteanyobstructionsingunandcable.Replacegunandcableifnecessary.

SeeWireDriveRollSectioninthismanualforproperinstallationofdriveroll.

Remove,clean,installandtighten.

Cleancableorreplaceliner.

Replace.

Replace.

Replace.

Replacecontacttip.

Setidlerollpressure.

Replacetip-removeanyspatteronendoftip.

Inspect-repairorreplaceasnecessary.

Besureelectrodeleadistight,guncabletightinwirefeedercontactblock,gunnozzleandguntiptight.Allworkleadconnectionsmustbetight.

Checkconnectionatoutputstudsforpolarityrequiredbyweldingprocess.

See“GasMetalArcWeldingGuide”(GS100).

Cleangas nozzle.Make certain that gas diffuser isnot restricted.Make certain that gas cylinder is notemptyorturnedoff.Makecertaingassolenoidvalveisoperatingandgasflowrateiscorrect.

Remove gun liner and check rubber seal for anysignofdeteriorationordamage.Besuresetscrewinbrassconnectorisinplaceandtightenedagainstthelinerbushing.

Donotexceedcurrentanddutycycleratingofgun.

A light application of high temperature antiseize lubricantmaybeappliedtotipthreads.

WARNING

ELECTRICSHOCKcankill

•Haveanelectrician installandservicethisequipment.

•Turntheinputpoweroffatthefuse box and unplug thema-chinebeforeworkingonequip-ment.

•Do not touch electrically hotparts.

Section 9 - TROUBLESHOOTING

IM6016 REDI-MIG®Plus215C,255C,255S Page25

PossibleCause

Defectivewirefeedmotororwiredrivecon-trolPCboard.

DefectivewiredrivecontrolPCboard.

Overtemperatureprotectioncircuitactuatedduetooverloadorshort.(Overtemperaturelightshouldbeilluminated).

Faultyguntriggerswitchordamagedcontrolcableconnectedtoguntrigger.

DefectivecontrolPCboard.

Defectivecontactor

Impropersettingsforwirefeedspeedandvolts.

Faultyswitcheithercoarsecontrol(on/off)orfinecontrol.

Faultypilottransformer.

Faultymaintransformer.

Faultyrectifier.

Faultychoke.

Onephasedisconnected.

WhatToDo

Measurethevoltagebetweenthemotorleads(54)and(53)whentheGasPurge/WireInchtoggle switch is pressed downwards. If thisvoltageisover10VDC,replacethewirefeedmotor.Ifnovoltageisregistered,replacethewire drive PCB. (Refer PCB replacement procedureonpage19).

Replace PCB. (Refer PCB replacement procedureonpage19).

Allowmachine to cool down and reduce ontimeand/orwirefeedspeed.

Repair.

Refer Procedure for Replacing PC Boards, if no fault is detected in trigger-thermostat circuit.

Replacedefectivecontactor

Setcontrolscorrectly.

Replaceswitch.

Replace.

Replace.

Replace

Replace.

Checkfuses,checkinputconnection.

Problem

Nowirefeed,althougharcvolt-ageispresent.

Nocontrolofwirefeed.

Nowirefeedandnoarcvoltage.Pilotlightindicatesinputpowertomachine.

Poorweldingcharacteristicsand/orcannotobtainfullratedoutputaspernameplate.

TROUBLESHOOTING

Page26 REDI-MIG®Plus215C,255C,255S IM6016

THELINCOLNELECTRICCO.Cleveland,Ohio,U.S.A.-SubsidiarycompaniesestablishedinAustralasia,Asia,Canada,Europe,NorthandSouthAmerica.

TheLincolnElectricCompany(Australia)Pty.Ltd.A.B.N.3600004030835BryantStreet,Padstow,Sydney2211,AustraliaTelephone: (02)97727222 Fax:(02)97922420International: Ph:+61297727222 Fax:+61297922420

In Australia, Lincoln Technical Sales Representatives are located in,Mackay, Bundaberg, Brisbane, Newcastle, Sydney, Wollongong,Melbourne,Adelaide andPerth. Tocontact your local LincolnTechnicalSalesRepresentative,call1300728720 (for thecostofa localcall).Lincolnproductsaresoldprimarilythroughitsdistributors.OurRegionalOfficelocationsare:NorthernRegion:Unit1/15WestgateSt,Wacol,Qld,4076 (07)32713000CentralRegion:35BryantStreet,Padstow,NSW,2211 (02)97727222SouthernRegion:8/2SartonRd,ClaytonVIC3168 (03)95900143WesternRegion:25BarkerStreet,Belmont,WA,6104 (08)92778744NewZealand:7B/761GreatSouthRoad,Penrose,Auckland (9)5804008Singapore:No.195,Lane5008,HutaiRoad, +862166026620

Baoshan,Shanghai,China201907

LIMITEDWARRANTY IM6016(1/06)

STATEMENTOFLIMITEDWARRANTYTheLincolnElectricCompany(Australia)PtyLimited(“Lincoln”)warrantsallnewmachineryandequipment(“goods”)manufacturedbyLincolnagainstdefectsinworkmanshipandmaterialsubjecttocertainlimitationshereinafterprovided.ThiswarrantyisvoidifLincolnoritsAuthorisedServiceFacilityfindsthattheequipmenthasbeensubjectedtoimproperinstallation,impropercareorabnormaloperations.PERIODOFWARRANTY“LINCOLNBRANDEDGOODS”Theperiodfromthecommencementofthewarrantyinrespectofgoodscoveredbythiswarrantyshallbeasfollows:ThreeYearsAllLincolnweldingmachines,wirefeedersandplasmacuttingmachinesunlesslistedbelow.TwoYearsAllWeldanpowers,RangersandItalianInvertecwelders.OneYearItalianPlasmas.•Allwatercoolers(internalandexternal).•Arcweldingandcuttingrobotsandroboticcontrollers.•Allstickelectrodes,weldingwiresandfluxes.•AllEnvironmentalSystemsequipment,includingportableunits,centralunitsandaccessories.(Doesnotincludeconsumableitemslistedunder30-daywarranty).

•Allweldingandcuttingaccessoriesincludingwirefeedmodules,undercarriages,fieldinstalledoptionsthataresoldseparately,unattachedoptions,weldingsupplies,standardaccessorysets,replacementparts.(Doesnotincludeexpendablepartsandguns/torcheslistedunder90and30daywarranties)

•All“ProTorch”TIGtorches.90Days•AllGunandCableAssemblies(manufacturedbyLincoln)andSpoolguns.•AllMIG,TIGandPlasmaTorches30Days•Allconsumableitemsthatmaybeusedwiththeenvironmentalsystemsdescribedabove.Thisincludeshoses,filters,beltsandhoseadapters.

•ExpendableParts-Lincolnisnotresponsibleforthereplacementofanyexpendablepartthatisrequiredduetonormalwear.

ENGINEWARRANTYTotheextentpermittedbylawLincolnshallbeentitledtoinitsabsolutediscretionrepairallenginesandengineaccessorieshoweverLincolnshallnotbeheld responsible foranysuchrepairwhichshallbethesoleresponsibilityoftheenginemanufacturerwhichprovidesforwarrantiesfortheperiodandsubjecttoanylimitationsprovidedforbythosemanufacturersoftherespectiveenginesandengineaccessories.ThreeYears*Deutz912EngineandAccessories *Subjecttoconditions(Warrantyservicecanonlybecarriedoutan imposedbyDeutz.authorisedDeutzservicedealer)CumminsB3.3EngineandAccessories *Subjecttoconditions(Warrantyservicecanonlybecarriedoutan imposedbyCumminsauthorisedCumminsservicedealer)TwoYearsPerkinsEnginesandAccessories(ThePerkinsDistributorOrganisation *Subjecttoconditionsprovidesallwarrantyservice(accessories imposedbyPerkinsincluded)forthePerkinsEnginespoweringgoodsmanufacturedbyLincoln.Briggs&StrattonVanguardEngines *TheMagnetronignitionandAccessories.(Warrantyservicecanonly systemiswarrantedbybecarriedoutbyanauthorisedBriggs&Stratton Briggs&Strattonfor5years.servicedealer).KubotaEnginesandAccessories *Subjecttoconditions(Warrantyservicecanonlybecarriedoutan imposedbyKubota.authorisedKubotaservicedealer)OneYear*RuggeriniEnginesandAccessories(WarrantyservicecanonlybecarriedoutbyauthorisedLincolnFieldServiceShoportheenginedistributorsauthorisedbytheLincolnbranchoffice).BATTERYWARRANTYLincolnsuppliescertainbatteriesinconnectionwithitssupplyofgoodsandthepurchaseracknowledgesthatanysuchbatteryiswarrantedbyitsmanufacturerandanyclaiminrespectofsuchabatterywhetherastoadefectinthebatteryorastodamageconsequentialuponadefectinabatteryshallbemadebythepurchasertothemanufacturerofthebatteryandthepurchasershallnotholdLincolninanywayliablefortheoperation,non-operationormalfunctionofanysuchbattery.

CONDITIONOFWARRANTYTOOBTAINWARRANTYCOVERAGE:ThepurchasermustcontactLincolnorLincoln’sAuthorisedServiceFacilityaboutanydefectclaimedunderLincoln’swarranty.DeterminationofwarrantyonweldingandcuttingequipmentwillbemadebyLincolnorLincoln’sAuthorisedServiceFacility.WARRANTYREPAIRIfLincolnorLincoln’sAuthorisedServiceFacilityconfirmstheexistenceofadefectcoveredbythiswarranty,thedefectwillbecorrectedbyrepairorreplacementatLincoln’soption.AtLincoln’srequest,thepurchasermustreturn,toLincolnoritsAuthorisedServiceFacility,any“Goods”claimeddefectiveunderLincoln’swarranty.FREIGHTCOSTSThepurchaserisresponsibleforshipmenttoandfromtheLincolnAuthorisedServiceFacility.WARRANTYLIMITATIONSCertainconditionswarrantiesandobligationsareimpliedbylaw(forexampleundertheTradePracticesAct1974)andcannotbeexcludedormodified(“thestatutorywarranties”).WherethestatutorywarrantiesdoapplythenanyexpresswarrantiesgivenbyLincoln(the“expresswarranties”)aregiveninadditionandwithoutderogationfromthestatutorywarranties.Apart from theexpresswarrantiesand (incaseswhere theyapplyby lawbutnototherwise)thestatutorywarrantiesLincolngivesnowarrantieswhetherexpressor implied by operation of lawor otherwise in respect of any goodsmanufactured orsuppliedbyLincolnorbyitsauthoriseddistributor.Anywarrantywhetherexpressor statutoryand the termofanysuchwarrantyas setout herein commences on the date Lincoln or Lincoln’s authorised distributorshipforwards thegoods from thepremisesofLincolnorLincoln’sauthoriseddistributor tothepurchaser.In respect of any claimunder thewarranty herein provideda purchasermust furnishLincolnwithwrittennoticeofanyclaimunderthewarrantywithinthetimeperiodofthewarrantyasfurtherspecifiedherein.TheextentofLincoln’swarrantywhetherexpressorstatutory is limited toa liability torepair,replaceorpaytothepurchaseranamountequalto: a) Thecostofreplacingthegoods; b) Thecostofobtainingequivalentgoods;or c) Thecostofhavingthegoodsrepairedwhicheverremedyinitsabsolute

discretionLincolnchooses.UponrequestbyLincolnthepurchasermustpermitLincolntoinspectthegoodsthesubjectofanyclaimunderthiswarrantyandLincolnmayatitsabsolutediscretionrepairorreplacethegoodsF.O.B.atitsownpremisesoratsuchotherpremisesasLincolnmaydesignateprovidedthatallfreightchargestoandfromLincoln’spremisesorsuchotherpremisesasLincolnmaydesignateshallbepaidbythepurchaser.SubjecttotheexpressandstatutorywarrantieshereinbeforeprovidedLincolnprovidesno other warranties in respect of themanufacture or sale of goods and in particularLincolnshallhavenoresponsibilityorliabilityinrespectof:a) RepairsdonetoLincoln’sgoodsandundertakenbythepurchaseroutsideLincoln’s

premiseswithoutwrittenauthorityfromLincolnobtainedpriortoanysuchrepair;b) Any damage or failure of the goods as a result of normalwear and tear or the

neglectmisuseabuseorfailuretoproperlyservicegoodsbyanypurchaser.TheliabilityofLincolnislimitedashereinbeforeprovidedandLincolnshallnotbeliableforanyincidentalspecialorconsequentialdamagesufferedbyapurchaserwhetherornotarisingoutofcircumstancesknownorforeseeableknownbyLincolnandinparticulararisingoutof thesupplyofgoods toapurchaseror theuseofgoodsbyapurchaserwhetherbasedonbreachofcontractnegligenceortort.CUSTOMERASSISTANCEPOLICYThebusinessofTheLincolnElectricCompanyismanufacturingandsellinghighqualityweldingequipment,consumables,andcuttingequipment.Ourchallengeistomeettheneedsofourcustomersandtoexceedtheirexpectations.Onoccasion,purchasersmayaskLincolnElectricforadviceorinformationabouttheiruseofourproducts.Werespondtoourcustomersbasedonthebestinformationinourpossessionatthattime.LincolnElectricisnotinapositiontowarrantorguaranteesuchadviceandassumesnoliability,withrespecttosuchinformationoradvice.Weexpresslydisclaimanywarrantyofanykind,includinganywarrantyoffitnessforanycustomer’sparticularpurpose,withrespecttosuchinformationoradvice.Asamatterofpracticalconsideration,wealsocannotassumeanyresponsibilityforupdatingorcorrectinganysuchinformationoradviceonceithasbeengiven,nordoestheprovisionofinformationoradvicecreate,expandoralteranywarrantywithrespecttothesaleofourproducts.Lincoln Electric is a responsive manufacturer, but the selection and use of specificproducts sold by LincolnElectric is solelywithin the control of, and remains the soleresponsibility of the customer. Many variables beyond the control of Lincoln Electricaffect the results obtained in applying this type of fabrication methods and servicerequirements.

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