Lincoln Electric REDI-MIG Plus 215C User manual
IM6016 REDI-MIG®Plus215C,255C,255S Page1
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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
IM6016
May 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 24
Section9 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 are
electrically“hot”whenthewelderison. Donottouch
these “hot” parts with your bare skin or wet clothing.
Weardry,hole-freeglovestoinsulatehands.
b. In semi-automatic and automatic wire welding, the
electrode,electrodereel,weldingheadandnozzleor
semi-automaticweldinggunarealsoelectrically“hot”.
c. Insulate yourself from work and ground using dry
insulation.Whenweldingindamplocations,onmetal
framework such as floors, gratings or scaffolds, and
when in positions such as sitting or Lying, make
certaintheinsulationislargeenoughtocoveryourfull
areaofphysicalcontactwithworkandground.
d. Always be sure the work cable makes a good
electricalconnectionwiththemetalbeingwelded.The
connectionshouldbeascloseaspossibletothearea
beingwelded.
e. Ground the work or metal to be welded to a good
electrical(earth)ground.
f. Maintain the electrode holder, work clamp, welding
cable and welding machine in good, safe operating
condition.Replacedamagedinsulation.
g. Neverdiptheelectrodeholderinwaterforcooling.
h. Never simultaneously touch electrically “hot” parts of
electrodeholdersconnected totwo weldersbecause
voltagebetweenthetwocanbethetotaloftheopen
circuitvoltageofbothwelders.
i. Whenworkingabovefloorlevel,protectyourselffrom
afallshouldyougetashock.
j. Alsoseeitems4cand6.
2. a. Weldingmayproducefumesandgaseshazardousto
health.Avoidbreathingthesefumesandgases.When
welding,keepyourheadoutofthefume.Useenough
ventilationand/orexhaustatthearctokeepfumesand
gases away from the breathing zone. When welding
ongalvanised,leadorcadmiumplatedsteelandother
metalswhichproducetoxicfumes,evengreatercare
mustbetaken.
b. Donotweldinlocationsnearchlorinatedhydrocarbon
vapourscomingfromdegreasing,cleaningorspraying
operations.Theheatandraysofthearccanreactwith
solventvapourstoformphosgene,ahighlytoxicgas,
andotherirritatingproducts.
c. Shielding gases used for arc welding can displace
air and cause injury or death. Always use enough
ventilation, especially in confined areas, to ensure
breathingairissafe.
d. Readandunderstandthemanufacturer’sinstructions
for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and
followyouremployer’ssafetypractices.
e. AlsoseeItem7b.
3. a. Use a shield with the proper filter and cover plates
toprotect youreyes fromsparks andthe raysof the
arc when welding or observing open arc welding.
Headshield and filter lens should conform to AS
1674.2-1990standards.
b. Use suitable clothing made from durable flame
resistantmaterialtoprotectyourskinandthatofyour
helpersfromthearcrays.
c. Protect other nearby personnel with suitable non
flammable screening and/or warn them not to watch
thearcorexposethemselvestothearcraysortohot
spatterormetal.
4. a. Removefire hazardsfromthe weldingarea.Ifthis is
notpossible,coverthemtopreventtheweldingsparks
from starting a fire. Remember that welding sparks
andhotmaterialsfromweldingcaneasilygothrough
smallcracksandopeningstoadjacentareas.Havea
fireextinguisherreadilyavailable.
b. Where compressed gases are to be used at the job
site, special precautions should be used to prevent
hazardous situations. Refer to AS1674 Parts 1 &
2 “Safety in Welding and Allied Processes”, WTIA
TechnicalNote7“HealthandSafetyinWelding”and
the operating information for the equipment being
used.
c. When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidentalcontactcancauseoverheatingandcreate
afirehazard.
d. Do not heat, cut or weld tanks, drums or containers
untiltheproperstepshavebeen takentoinsure that
such procedures will not cause flammable or toxic
vapoursfromsubstancesinside.Thesecancausean
explosioneventhoughthevesselhasbeen“cleaned”.
ForinformationrefertoAS1674.1&.2(latesteditions).
e. Vent hollow castings or containers before heating,
cuttingorwelding.Theymayexplode.
f. Sparks and spatter are thrown from the welding arc.
Wear oil free protective garments such as leather
gloves,heavyshirt,cufflesstrousers,highshoesand
acapoveryourhair.Wearearplugswhenweldingout
ofposition orinconfinedplaces.Always wearsafety
glasseswithsideshieldswheninaweldingarea.
g. Connect the work cable to the work as close to the
welding area as possible. Work cables connected to
the building framework or other locations away from
theweldingareaincreasethepossibilityofthewelding
currentpassingthroughliftingchains,cranecablesor
otheralternatecircuits.Thiscancreatefirehazardsor
overheatliftingchainsorcablesuntiltheyfail.
h. AlsoseeItem7c.
FUMES AND GASES
can be dangerous
ARC RAYS can burn
WELDING SPARKS can
cause fire or explosion
Page4 REDI-MIG®Plus215C,255C,255S IM6016
5. a. Use only compressed gas cylinders containing
the correct shielding gas for the process used and
properly operating regulators, designed for the gas
andpressure used.Allhoses, fittings,etc. shouldbe
suitable for the application and maintained in good
condition.
b. Always keep cylinders in an upright position and
securely chained to an undercarriage or fixed
support.
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, sparks
orflame.
d. Never allow the electrode, electrode holder, or any
otherelectrically“hot”partstotouchacylinder.
e. Keepyourheadandfaceawayfromthecylindervalve
outletwhenopeningthecylindervalve.
f. Valve protection caps should always be in place
and hand-tight except when the cylinder is in use or
connectedforuse.
g. Read andfollow theinstructions oncompressed gas
cylinders and associated equipment, and AS 2030
Parts1&2.
6. a. Turnoffinputpowerusingthedisconnectswitchatthe
fuseboxbeforeworkingontheequipment.
b. Install equipmentin accordancewith theSAA Wiring
Rules,alllocal codesandthemanufacturer’s recom-
mendations.
c. Earth the equipment in accordance with the SAA
Wiring Rules and the manufacturer’s recommenda-
tions.
7. a. Turn the engine off before troubleshoot-
ing and maintenance work unless the
maintenance work requires it to be
running.
b. Operate engines in open, well ventilated
areas or vent the engine exhaust fumes
outdoors.
c. Donotaddfuelnearanopenflame,welding
arcorwhentheengineisrunning.Stopthe
engineandallowittocoolbeforerefuelling
toprevent spilledfuel fromvaporizingon
contactwithhotenginepartsandigniting.
Donotspillfuelwhenfillingtank.Iffuelis
spilled,wipeitupanddonotstartengine
untilfumeshavebeeneliminated.
d. Keepallequipment,safetyguards,covers
anddevicesinpositionandingoodrepair.
Keephands,hair,clothingandtoolsaway
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairingequipment.
e. In some cases it may be necessary to
removesafetyguardstoperformrequired
maintenance. Remove guards only when
necessary and replace them when the
maintenance requiring their removal is
complete. Always use the greatest care
whenworkingnearmovingparts.
f. Donotputyourhandsneartheenginefan.
Donotattempttooverridethegovernoror
idlerbypushingonthethrottlecontrolrods
whiletheengineisrunning.
g. To prevent accidentally starting petrol
engineswhileturningtheengineorwelding
generator during maintenance work,
disconnectthesparkplugwires,distributor
capormagnetowireasappropriate.
h. To avoid scalding do not remove the
radiatorpressurecap whentheengineis
hot.
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
HOWTOORDERREPLACEMENTPARTS
Toensurethatyoureceivethecorrectreplacementpartthefollowingprocedureshouldbefollowed:
1. QuoteSerialNumberandCodeNumber.
2. QuotetheDescription,ItemNumberandParts ListNumberofthe desiredpart.Whenorderingparts foritemscarryingbrand
namesofothercompanies,suchasfanmotors,driveshafts,etc.,besuretoincludetheothercompany’snameandpartnumber
andotherrelevantinformation.
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 are
not considered replaceable items. This is to ensure that the customer receives parts which will keep the welder in the best operating
condition.
BUYONLYGENUINEREPAIRPARTS
Formoredetailedinformationitisstronglyrecommendedthatyoupurchaseacopyof“SafetyinWeldingandCutting-ANSIStandardZ
49.1”andWTIATechnicalNote7.AllWTIApublicationsandANSI/AWSStandardsareavailablefromtheWeldingTechnologyInstituteof
Australia,P.O.Box6165,SilverwaterNSW2128.ForcopiesofvariousAustralianStandardscontactyourlocalS.A.A.office.
Formoredetailedinformationitisstronglyrecommendedthatyoureviewcopiesof“SafetyinWeldingandAlliedprocesses-AS1674.1&
.2”andWTIATechnicalNote7–TN07.AustralianStandardsareavailablefromSAIGlobal–www.saiglobal.comandWTIApublications
areavailablefromtheWeldingTechnologyInstituteofAustralia–www.wtia.com.au.
IM6016 REDI-MIG®Plus215C,255C,255S Page5
WELDING, EMF & PACEMAKERS
All welders should follow safe practices that minimise their
exposuretoelectricandmagneticfields(EMF).
For welders wearing implanted pacemakers, safe welding
practices are particularly important and additional procedures
should be followed by those who have decided to continue to
weld.(Hopefullyinkeepingwithadoctor’sadvice).
Thefollowingprocedures willnoteliminate exposuretoEMFor
the possibility of arc welding having an effect on a pacemaker,
however if followed, they will significantly reduce exposure to
electric and magnetic fields. Electric and magnetic fields are
created any time electric current flows through a conductor,
however it is not clear whether such exposure affects ones
health.
Some researchers have reported that exposure to EMF may
causeleukemiaorotherillnesses.Theseclaimsoriginallyarose
inrelationtohighvoltageelectricpowerlinesandareverymuch
indisputeinthemedicalandscientificarena,however thebest
adviceistominimiseyourexposuretoEMFtoprotectyourhealth
shoulddoctorseventuallydecidethereisarisk.
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
AllweldersshouldusethefollowingprocedurestominimiseEMF
exposure.
• Routeelectrodeorgunandworkcablestogether.Secure
themwithtapeifpossible.
• Nevercoiltheelectrodeleadaroundyourbody.
• Do not place your body between the electrode and work
cables.Ifyourelectrodecableisonyourrightsidethework
cableshouldalsobeonyourrightside.
• Connect the work cable to the work piece as close as
possible to the area being welded. (This is also a good
practice to eliminate a common problem on welding - a
poorworkconnection.
• Donotworknexttotheweldingpowersource.
Welders with pacemakers
Thereis noquestion thatthe fieldsin arcwelding caninterfere
withapacemakersfunction.Generallytheinterferencedoesnot
permanentlydamagethepacemaker.Oncethewearerleavesthe
arcweldingenvironmentorstopswelding,thepacemakerreturns
tonormal functioning.The weldingarc haslittle orno effecton
the operation of some pacemakers, especially designs that are
bi-polarordesignedtofilteroutsuchinterference.
Forawelderoranyoneworkingaroundelectricalequipmentthe
selectionofapacemakerisveryimportant.Getadoctor’sadvice
aboutwhichpacemakeristheleastsensitivetointerferencefrom
weldingwhilestillbeingmedicallysuitable.
Inadditiontothenormalsafetyprecautions,thefollowingadditional
proceduresshouldbeadoptedbywelderswithpacemakers.
• Usegasweldingwhentheapplicationissuitable.
• Use the lowest current setting appropriate for the
application. Do not exceed 400 amps. Low current
(75-200amps)directcurrent(DC)weldingshouldbeused
if arc welding is necessary. Do not TIG weld with high
frequency.
• Donotuserepeated,shortwelds.Waitabouttenseconds
between stopping one weld and starting the next. When
havingdifficulty startinganelectrode, donotre-strike the
rodrepeatedly.
• If you feel light headed, dizzy or faint, immediately stop
welding.Laytheelectrodeholderdownsothatitdoesnot
contacttheworkandmoveawayfromanyweldingbeing
performed. Arrange your work in advance so that, if you
becomedizzyanddroptheelectrodeholder,theelectrode
holderwillnotfallonyourbodyorstrikethework.
• Donotworkonaladderorotherelevatedpositionorina
cramped,confinedplace.
• Do not work alone. Work only in the presence of an
individual who understands these precautions and the
possibleeffectweldingmayhaveonyourpacemaker.
• Donotworknearspotweldingequipment.
• Ifyouhaveapacemakerandwishtocontinuearcwelding,
discuss this and any other questions you may have with
your physician and follow his or her advice. The doctor
may wish to contact the pacemaker manufacturer for a
recommendation.As mentionedbefore,the designofthe
pacemaker significantly affects the degree to which it is
subjectto interferencefrom awelding circuit.Do notrely
onthefactthatyouknowanotherwelderwithapacemaker
whohasweldedforyearswithoutexperiencingaproblem.
That welder and his or her pacemaker may be quite
differentfromyouandyourpacemaker.
Page6 REDI-MIG®Plus215C,255C,255S IM6016
Conformance
Products displaying the C-Tick mark are in conformity with
Australian/New Zealand requirements for Electromagnetic
Compatibility(EMC).Theyare:
• manufactured in conformity with Australian/New Zealand
Standard (Emission):- AS/NZS 3652 ‘Electromagnetic
Compatibility - Arc Welding Equipment’ (Identical to and
reproducedfromBritishStandardEN50199)
• forusingwithotherLincolnElectric/LiquidArcequipment.
• designedforindustrialandprofessionaluse.
Introduction
All electrical equipment generates small amounts of electro-
magnetic emission. Electrical emission may be transmitted
throughpowerlinesorradiatedthroughspace,similartoaradio
transmitter. When emissions are received by other equipment,
electrical interference may result. Electrical emissions may
effectmany kindsofelectrical equipment:other nearbywelding
equipment, radio and TV transmitters and receivers, numerical
controlled machines, telephone systems, computers, etc. Be
aware that interference may result and extra precautions may
berequiredwhenaweldingpowersourceisusedinadomestic
establishment.
Installation and Use
The purchaser/user is responsible for installing and using the
weldingequipmentaccordingtothemanufacturer’sinstructions.
Ifelectromagneticdisturbancesaredetectedthenitshallbethe
responsibility of the purchaser/user of the welding equipment
to resolve the situation with the technical assistance of the
manufacturer. In some cases this remedial action may be as
simple as earthing (grounding) the welding circuit (see note
below). In other cases it could involve constructing an elec-
tromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases electromag-
neticdisturbancesmustbereducedtothepointwheretheyare
nolongertroublesome.
Note:Theweldingcircuit mayormaynotbeearthedforsafety
reasons according to national codes. Changing the earthing
arrangements should only be authorised by a person who is
competent to assess whether the changes increase the risk of
injury,eg.byallowingparallelweldingcurrentreturnpathswhich
maydamagetheearthcircuitsofotherequipment.
Assessment of Area
Before installing welding equipment the purchaser/user shall
make an assessment of potential problems in the surrounding
area.
Thefollowingshallbetakenintoaccount:
a. Other supply cables, control cables, signalling and
telephonecablesabove,belowandadjacenttothewelding
equipment;
b. Radioandtelevisiontransmittersandreceivers;
c. Computerandothercontrolequipment;
d. Safetycriticalsafetyequipment,eg.guardingofindustrial
equipment;
e. The healthof peoplearound, eg. theuse ofpacemakers
andhearingaids;;
f. Equipmentusedforcalibrationormeasurement;
g. Theimmunityofotherequipmentintheenvironment.The
purchaser/user shall ensure that other equipment being
used in the environment is compatible. This may require
additionalprotectionmeasures;
h. Thetimeofthedaythatweldingorotheractivitiesaretobe
carriedout.
The size of the surrounding area to be considered will depend
onthestructureofthebuildingandotheractivitiesthataretaking
place.Thesurroundingareamayextendbeyondtheboundaries
ofthepremises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply
accordingtothemanufacturer’srecommendations.Ifinterference
occurs,itmaybenecessarytotakeadditionalprecautionssuch
as filtering the mains supply. Consideration should be given
to shielding the supply cable of permanently installed welding
equipmentinmetallicconduitorequivalent.Shieldingshouldbe
electricallycontinuousthroughoutitslength.Theshieldingshould
beconnectedtotheweldingpowersourcesothatgoodelectrical
contactismaintainedbetweentheconduitandtheweldingpower
sourceenclosure.
Maintenance of the Welding Equipment
Theweldingequipmentshouldberoutinelymaintainedaccording
tothemanufacturer’s recommendations.Allaccessand service
doorsandcoversshouldbeclosedandproperlyfastenedwhen
the welding equipment is in operation. The welding equipment
should not be modified in any way except for those changes
and adjustment covered in the manufacturer’s instructions.
In particular, the spark gaps of arc initiation and stabilising
devices should be adjusted and maintained according to the
manufacturer’srecommendations.
Welding Cables
The welding cables should be kept as short as possible and
should be positioned close together, running at or close to the
floorlevel.
Equipotential Bonding
Bonding of all metallic components in the welding installation
and adjacent to it should be considered. However, metallic
componentsbondedtotheworkpiecewillincreasetheriskthat
the operator could receive a shock by touching these metallic
components and the electrode at the same time. The operator
shouldbeinsulatedfromallsuchbondedmetalliccomponents.
Earthing of the workpiece
Wheretheworkpieceisnotbondedtoearthforelectricalsafety,
norconnectedtoearthbecauseofitssizeandposition,eg.ship’s
hull or building steelwork, a connection bonding the workpiece
to earth may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of work pieces
increasingtheriskofinjurytousers,ordamagetootherelectrical
equipment.Wherenecessary,theconnectionoftheworkpieceto
earthshouldbemadebydirectconnectiontotheworkpiece,but
insome countrieswhere directconnection isnot permitted,the
bonding should be achieved by suitable capacitance, selected
accordingtonationalregulations.
Screening and Shielding
Selectivescreeningandshieldingofothercablesandequipment
in the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered
forspecialapplications.*
* Portions of the preceding text are contained in AS/NZS3652:
‘ElectromagneticCompatibility-ArcWeldingEquipment’.
INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
Thisweldingmachinemustbeusedbytrainedoperators
only.Readthismanualcarefullybeforeattemptingtouse
theweldingmachine.
WARNING
IM6016 REDI-MIG®Plus215C,255C,255S Page7
Pleaserecordyourequipmentidentificationinformationbelowforfuturereference.Thisinformationcanbefoundon
yourmachinenameplate.
ModelName&Number ________________________________________
Code&SerialNumber ________________________________________
DateofPurchase ________________________________________
Wheneveryourequestreplacementpartsorinformationonthisequipment,alwayssupplytheinformationyouhave
recordedabove.
Thank You forselectingaQUALITYproductbyLincolnElectric.Wewantyoutotake
prideinoperatingthisLincolnElectricCompanyproduct-asmuchpride
aswehaveinbringingthisproducttoyou!
ReadthisOperator’sManualcompletelybeforeattemptingtousethisequipment.Savethismanualandkeepithandy
forquick reference.Pay particularattention tothe SafetyInstructions wehave providedfor yourprotection. Thelevelof
seriousnesstobeappliedtoeachisexplainedbelow:
This statement appears where the information must be
followed exactly to avoid serious personal injury or loss
oflife.
WARNING
This statement appears where the information must be
followedto avoidminorpersonalinjuryor damagetothis
equipment.
CAUTION
Page8 REDI-MIG®Plus215C,255C,255S IM6016
Machine Installation
1.1 Location
Place the welder where clean cooling air can freely
circulateinthroughthebacklouversandoutthroughthe
frontlouvres.Dirt,dustoranyforeignmaterialthatcanbe
drawnintotheweldershouldbekeptataminimum.Failure
to observe these precautions can result in excessive
operatingtemperaturesandnuisancethermostattrips.
1.2 Connection to Mains Supply
Beforeconnectingthemachinetothemainssupplycheck
that the voltage and current capacity correspond to the
machinevoltageandratedinputcurrent.UseafuseorC/B
perAS3000orlocalwiringrules.
Themachineissuppliedwithaninputleadfitted.
Haveaqualifiedelectricianfitasuitableinputplug.
The REDI-MIG® Plus 215C, 255C and 255 are supplied
withfactoryfitted240volt15ampplug.
•Turntheinputpower off att h e
disconnectswitchbeforeinstalling
orservicingthismachine.
•Donottouch elec tric all y
“hot”partssuchasoutput
terminalsorinternalwiring.
•Connectearthingscrew()toa
goodearthground.
•Donotoperatewithcovers
removed.
•Turnpowerswitch“off”before
connectingordisconnecting
cablesorotherequipment.
WARNING
HIGH
VOLTAGE
cankill
Onlyqualifiedpersonnelshouldinstallorservicethisequipment.
PRODUCT DESCRIPTION
The REDI-MIG® Plus family is the latest development in step controlled MIG welding machines designed and built by Lincoln Electric.
LincolnElectric’snewREDI-MIG®Plusfamilycomprisesofthreemodelsinbothcompactandseparatewirefeeder.TheREDI-MIG®Plus
215C,255Cand255Sarefor240voltsupply.Excellentarccharacteristicsareprovidedforgasshieldedandselfshieldedweldingwithin
therespectivemachine’scurrentranges.
Section 1 - INSTALLATION
Never connect the green/yellow conductor to any of the
active supply lines from the mains. This conductor is to
earth the machine as required by Electrical Regulations.
Once the above has been followed the machine can be
pluggedintothemainsoutlet.
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 AC
5 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 the
processbeingused.
1. Set gas cylinder on rear platform of the machine. Hook
chaininplacetosecurecylindertorearofwelder.
2. Remove the cylinder cap. Inspect the cylinder valve for
damaged threads, dirt and dust. For cylinders having an
external thread fitting, remove any dust and dirt from the
threadswithacleancloth.
DO NOT ATTACH THE REGULATOR/FLOWMETER
IF OIL, GREASE OR CYLINDER VALVE DAMAGE IS
PRESENT. OIL OR GREASE IN THE PRESENCE OF
HIGHPRESSUREOXYGENISEXPLOSIVE!Informyour
gassupplierofthiscondition.
3. Stand to one side away from the outlet and open the
cylindervalveforaninstant.Thisblowsawayanydustor
dirtwhichmayhaveaccumulatedinthevalveoutlet.
4. Inspect the regulator/flowmeter for damaged threads and
seals,dirtanddust.Removedustanddirtwithacleancloth.
DO NOT USE THE REGULATOR/FLOWMETER IF
DAMAGEISPRESENT!Haveanauthorisedrepairstation
repairanydamage.
5. Attach the regulator/flowmeter to the cylinder valve and
tightentheunionnut(s)securelywithaspanner.
6. Attach themachines inletgas hoseto theoutlet fittingof
theregulator/flowmeter,andtightentheunionnutsecurely
withaspanner.
7. Before opening the cylinder valve, turn the regulator
adjustingknobcounter-clockwiseuntiltheadjustingspring
pressureisreleased.
8. Openthecylinder valveslowlyafraction ofaturn.When
the cylinder pressure gauge pointer stops moving, open
thevalvefully.
9. The regulator/flowmeter is adjustable. Set it for the flow
rate recommended for the procedure and process being
usedbeforestartingtoweld.
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 front
panelgunconnectorandthenjointheconnectorsand
tightenthehandnutontheguncableconnector.
Note: If a gun and cable other than the supplied gun is
to be used, it must conform to standard European-style
connectorspecifications.SeePicture.
The gun trigger switch must be capable of switching 10
milliampsat60voltsDC—resistive.
1.5 Output Polarity Connection 215C and 255C
only
Theelectrodecableislocatedbetweenoutputterminals.
Theelectrodecableisconnectedtotherequiredoutputterminal
onthefrontoftheREDI-MIG®Plus215Cand255C.
Thegunpolaritycanbechangedbyplacingtheelectrodecableto
therequiredoutputterminal,eg.forelectrode(-)ve,connectthe
electrodecabletothe(-)veoutputstud.Connecttheworkleadto
theotheroutputterminal.
Output Polarity Connection 255S
The PWF4S wire feeder is connected to the REDI-MIG® Plus
255S separate power source via a control/electrode/gas cable
assembly. The electrode cable is connected to the required
outputterminalonthefrontoftheREDI-MIG®Plus255Sseparate
powersource.
The control cable connects to the plug on the front of the
REDI-MIG®Plus255Sseparatepowersource,betweentheoutput
terminals.
The gun polarity can be changed by placing the electrode
cable to the required output terminal on the front of the
REDI-MIG® Plus 255S, eg. for electrode (-)ve,
connect the electrode cable to the (-)ve output terminal.
Connecttheworkleadtotheotheroutputterminal.
Gas under pressure is explosive. Always keep gas
cylindersinanuprightpositionandalwayskeepchained
to undercarriage or stationary support. Refer “Safety in
Welding and Cutting” - ANSI Standard Z49-1 and WTIA
Technical Note 7 available from the Welding Technology
InstituteofAustralia.
WARNING
Never stand directly in front of or behind the regulator/
flowmeterwhenopeningthecylindervalve.Alwaysstand
tooneside.
The gun trigger switch connected to the gun trigger
controlcablemustbeanormallyopen,momentaryswitch.
The terminals of the switch must be insulated from the
welding circuit. Improper operation of, or damage to,
the machine might result if this switch is common to an
electricalcircuitotherthanthemachinetriggercircuit.
CAUTION
Turnthewelderpowerswitchoffbeforeinstallinggunand
cable.
WARNING
Turn the welder power switch off before changing
polarity.
Referto“SafetyinWeldingandCutting”-ANSIStandard
Z49-1 and WTIA Technical Note 7 available from the
WeldingTechnologyInstituteofAustralia.
Please also refer to “Safety in Welding and Allied
processes-AS1674.1&.2”andWTIATechnicalNote7–
TN07.AustralianStandardsareavailablefromSAIGlobal
–www.saiglobal.comandWTIApublicationsareavailable
from 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 215C
REDI-MIG®®
Plus 255C
REDI-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-in
indicatorlight.
2. OVER TEMPERATURE LIGHT – Indicateswhenexceeding
dutycyclei.e.basedon10minutetimeperiodfor60%duty
cycle,ifactualweldingtimeexceeds6minutesthelightwill
comeon.Theinputpowerremainsonkeepingthecoolingfan
operative.
3. WIRE FEED SPEED CONTROL (WFS) – Usethiscontrolto
adjustthespeedatwhichthewirefeedswhenwelding.This
isineffectacurrentcontrolasthepowersourcewilldeliver
thecurrentnecessarytomeltthewire.Thehigherthespeed,
themorecurrentwillberequired.Wirefeedspeedrangeis
approximately1to20m/min.
Operationoftheguntriggerswitchesthewirefeedmotoron
andoff.Thewirefeedmotorisdynamicallybrakedtominimise
wireoverrunafterweldinghasceased.
4. TORCH CONNECTION – Eurotorchconnection
5. ARC VOLTAGE CONTROL –Theoutputvoltageiscontrolled
byrotaryswitch.Thisislocatedontheseparatewirefeederof
theREDI-MIG255S.
Theapproximateweldvoltagesfortherotaryswitchpostionsfor
the215C,255Cand255Sareabove.
6. AMPERAGE AND VOLTAGE METER - Digitalmeterdisplays
weldingvoltage.SuppliedasstandardonREDI-MIG®Plus
255S.AvailableasafieldfitoptionforotherREDI-MIG®Plus
models.
WARNING
ELECTRIC
SHOCK
cankill
FUMESAND
GASEScanbe
dangerous
WELDINGSPARKS
cancausefireor
explosion
•Donottouchelectricallylive
partsorelectrodewithskinor
wetclothing.
•Insulateyourselffromwork
andground.
•Alwaysweardryinsulating
gloves.
•Keepyourheadoutoffumes.
•Useventilationorexhaustto
removefumesfrombreathing
zone.
•Keepflammablematerial
away.
•Donotweldupon
containerswhichhave
heldcombustibles.
•Weareye,earandbody
protection.
ARCRAYS
canburn
IMPORTANTSAFETYNOTE:In2Tmode{referpoint10
below}, this DC Constant Voltage wire welder provides
“COLD” electrode when the gun trigger is not operated.
Conversely, the output terminals are “LIVE” when the
gun trigger is “activated” when pressed in 2T mode, or
triggeredonin4Tmode.
Section 2 - OPERATING INSTRUCTIONS
IM6016 REDI-MIG®Plus215C,255C,255S Page11
Section 2 - OPERATING INSTRUCTIONS
7. Spool Gun Connection -Connectionfortheoptionalspool
gunonthe215Cand255C.
8. GAS PURGE/WIRE INCH – Atwopositiontoggleswitch
locatedontheREDI-MIG®Plus4sUsethegaspurge
momentarytoggleswitchtooperatethegassolenoidtopurge
airfromthegassupplyafterconnectinganewgascylinder.Gas
purgewillonlyoperatewhilethetoggleswitchisheldupwards.
Usethesametoggleswitchtooperatethewirefeedmotorand
“cold”inchthewire,bypushingthetoggleswitchdownwards.
9. 2 STEP/4 STEP TRIGGER OPERATION –Atwoposition
toggleswitchlocatedinsidethewirefeederdoorofthe
REDI-MIG®215Cand255C.Thisprovidestwomodesof
operationoftheguntrigger.In2stepmode,theguntriggeris
pressedtostartweldingandreleasedtostop.
Inthe4stepmode,pressingtheguntriggeronlyoperatesthe
gassolenoid,allowingshieldinggastoflow.Releasingthegun
triggeractivatesthecontactorwhichstartsthewirefeedmotor
andconnectsweldingcurrenttothewiresothatweldingmay
commence.Tostopwelding,thetriggermustagainbeoperated;
pressingitstopsthewirefeed,activatestheburnbacktime
delayandopensthecontactorafterthepre-setburnbacktime.
Releasingthetriggerstopsthegasflow.
Torecommencewelding,theabovecyclemustberepeated.
10. Output Terminals –Dinseconnectionusedtoconnect
electrodecableandworkreturnlead.
FOROUTPOLARITYCONNECTIONREFERTOSECTION1.5
11. CONTROL CABLE OUTPUT CONNECTION - Thecontrol
cableconnectstotheoutputconnectionplugonthefrontofthe
REDI-MIG®Plus255Spowersourceabovetheoutputterminals.
Thecontrolcableisusedtoconnectthewirefeedertothe
powersource.
BURNBACK CONTROL –Thiscontrolislocatedinthewire
feedbay.Theburnbackcontroladjuststhetimeperiodfrom
whenthedrivemotorstopsuntilthepowersourceandgas
solenoidareswitchedoff(approximately0.1secondswhenfully
anti-clockwiseto1.1secondswhenadjustedfullyclockwise).
Thepurposeoftheburnbackcontrolistopreventtheelectrode
wirestickingintheweldcrateratthefinishoftheweld.
1
2
5
74
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 the
consumablebeingused.(LINCGunMIGgunissupplied).
3) Correctdriverollsforthewiresizeandtypetobeused.The
REDI-MIG®Plus215Cand255Caresuppliedwitha0.8-
0.9mmdriveroller.TheREDI-MIG®Plus255Saresupplied
witha 0.9-1.2mm driveroller.Drive rollsforother types
andsizesareavailableasspareparts.(Seetableonpage
16).
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/flowmeter
andhosearesupplied.)Ifgasshieldingisrequired,connect
thegashose.
Remember that gas cylinders may explode if damaged, so
ensurethatallgascylindersaresecurelymounted. Ensurethat
the correct type and size wire feed rolls are fitted. In replacing
wire feed rolls, ensure that the key and keyway are correctly
positionedandtightentheknurledlockingscrewsecurely.
Fit a spool of appropriate wire onto the spool so that it turns
clockwiseasthewireisfed.
Carefullyreleasetheendofthewirefromthespoolensuringthat
thereleasedendisheldtostopthewirefromunravelling.Cutoff
theendkinktogiveasmoothstraightendofwire.
Obtain a gap between the wire feed roll and the pressure roll
by lifting the cam latch. Feed the wire end into the guide tube,
betweenthedriverolls,andintothe“Euro”connectorguideuntilit
protrudesabout20mmoutofthefrontofthe“Euro”connector.
Close the drive rolls by lowering the cam latch ensuring the
rolls firmly hold the wire. Adjust the tension so that wire feeds
smoothly.Donotovertighten.
Fit the gun and cable assembly onto the “Euro” connector by
slippingtheendofwireintothecablewirehole.
Tightenthe“Euro”connectorlockring.
Activatethepowersource;setthewirefeedspeedto4onthedial
andpresstheguntriggerorwireinchpushbutton(iffitted).The
wirefeedrollshouldturn,feedingthewirefurtherupthegunand
cableassembly.Ensuretherearenokinksorsharpbendsinthe
guncableand holdthe guntrigger or wireinch buttonuntil the
wireemergesfromthegun.Itisgoodpracticetoremovethetip
whenfirstfeedinganewcoilofwire,thenrefittingoverthewire
andtightening.Cutofftheendofthewireleaving10mmto15mm
stick-out.Selectrequiredpolarity.SeeSection1.5
Section 3 - SETTING UP FOR WELDING
AC1400
1
2
3
4
56
7
8
9
10
.024 in.
0.60 mm
.030 in.
0.80 mm
.036 in.
1.0 mm
.048 in.
1.2 mm
.060 in.
1.6 mm
.075 in.
2.0 mm
.105 in.
2.5 mm
.135 in.
3.5 mm
3/16 in.
5.0 mm
1/4 in.
6.0 mm
5/16 in.
8.0 mm
10 - 15 L/min
*-
REDI-MIG
PLUS 215C
ALUMINIUM
77% Argon 23% CO2*
1
2
3
4
567
8
1
2
3
4
56
7
8
9
10
1
2
3
4
567
8
SuperGlaze®
4043, 5356
UltraMag® S6 / EasyMIG™S6
0.9mm 1.2mm 0.8mm 0.9mm 0.8mm 0.9mm 0.9mm 1.2mm
0.9mm 1.2mm 0.9mm 0.9mm 1.2mm 0.9mm 1.2mm
0.9mm 2 2 2 2
3 3.25 3 2.25 3 2.5
2 2
4 7 4 5.5
N/A N/A
N/R N/R N/R N/R
N/A N/A
3 2.53 2 3 2
2 2
6 4 6 3.25 5 2.5 6 6.75 6 5.56 36 2.5 6 3.5
8 4 8 4 7 3.5 7 7 9 5.258 3.58 3.5 8 4.5
12 5 12 5.25 11 411 5 11 3
1.6mm
4.0mm
8.0mm
12.0mm
REDI-MIG
PLUS 255C
0.9mm
2 4.25 4 3 6 2 N/A N/A
N/R N/R
3 23 2
N/A N/A
3 4.25 6 3.5 6 2.5 6 66 2.56 3.5
4 5.5 9 3.25 8 2.25 7 7 7 59 39 4
N/R N/R 6 6 11 3.5 12 3.25 9 5.5N/R N/R
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A
N/R N/R
1.2mm
4 2
6 3
8 3
11 3
1.6mm
4.0mm
8.0mm
11.0mm
100% CO2 * 100% Argon *
Innershield® - FCAW
77% Argon 23% CO2 *
SuperGlaze®
5356
UltraMag® S6 / EasyMIG™S6
100% CO2 * 100% Argon *
Innershield® - FCAW
No Gas Required
No Gas Required
AUS 1300 LINCOLN
NZ 0800 728 720
CONSUMABLE PARTS
LINC Gun® LG240G (REDI-MIG PLUS 215C & 255C)
Contact Tip M6 0.6mm LG240G KP10440-06
Contact Tip M6 0.8mm LG240G KP10440-08
Contact Tip M6 0.9mm LG240G KP10440-09
Contact Tip M6 1.2mm LG240G KP10440-12
Contact Tip M6 0.9mm Alum LG240G KP10441-09A
Contact Tip M6 1.0mm Alum LG240G KP10441-10A
Contact Tip M6 1.2mm Alum LG240G KP10441-12A
Nozzle 12mm LG240G KP10461-4
Tip Holder M6 LG240G KP10455-1
Gas Diffuser LG240G KP10404-WT
Liner 0.8-1.0mm 4m LG240G KP10413-4M
Liner 1.0-1.2mm 4m LG240G KP10414-4M
Liner 1.2-1.6mm 4m LG240G KP10415-4M
Liner 0.8-1.0mm 4m Teяon LG240G KP10422-4M
Liner 1.0-1.2mm 4m Teяon LG240G KP10418-4M
DRIVE ROLLERS
Drive Roll Kit 0.6/0.8mm KP61015-08
Drive Roll Kit 0.8/0.9mm KP61015-09
Drive Roll Kit 0.9/1.2mm KP61015-0912
Drive Roll Kit 0.9/1.2mm Alum KP61015-0912A
Driver Roll Kit 1.0/1.2mm KP61015-12
Drive Roll Kit 0.9/1.2mm FCW KP61015-0912R
Driver Roll Kit 1.2/1.6mm FCW KP61015-16R
Suggested settings for welding with the REDI-MIG® PLUS 215C & 255C
9mm
N/A = Not applicable
N/R = Not Recommended
1
2
3
4
56
7
8
9
10
.024 in.
0.60 mm
.030 in.
0.80 mm
.036 in.
1.0 mm
.048 in.
1.2 mm
.060 in.
1.6 mm
.075 in.
2.0 mm
.105 in.
2.5 mm
.135 in.
3.5 mm
3/16 in.
5.0 mm
1/4 in.
6.0 mm
5/16 in.
8.0 mm
* * * * * * * * *
10-15L/min
*-
AUS1300LINCOLN
NZ0800728720
9mm
All welds done in downhand position using recommended gas flow settings
0.9mm 1.2mm 0.9mm 0.9mm 1.2mm 0.9mm 1.2mm
4 3 5 2.5 3 5.5 N/R N/R4 2.53 2.5
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A
N/A N/A
N/R N/R
4 3
6 3.5 6 3 6 7.25 5 4.56 36 3.5 64
8 4.5 8 3.25 8 7.5 8 69 39 5.5 8 5
12 5.5 10 7N/A N/A N/R N/R 6 6
1.2mm
4 3
6 3.5
8 4
11 5
REDI-MIG
Æ
PLUS255S
77%Argon23%CO2*
1
2
3
4
567
8
1
2
3
4
56
7
8
9
10
1
2
3
4
567
8
SuperGlazeÆ
5356
UltraMagÆ
S6/EasyMIGôS6
1.2mm 0.8mm 0.9mm 1.2mm 1.2mm 1.2mm 0.9mm 1.2mm
0.9mm
1.6mm
4.0mm
8.0mm
12.0mm
REDI-MIG
Æ
325c&325s
0.9mm 1-4 1.5
1.7 3 2-2 2.75 1-1 1 1-1 5.5 1-2 41-8 3.5
1-4 2.5
4-7 7.5
1-7 2
2.5 3 2-2 2.5 2-2 2.5 2-4 6.25 2-3 4.752-4 3.53-4 4.5 2-4 2.5
3.5 5 3-1 2.75 2-4 2.5 3-1 9 2-7 53-4 5.753-6 4.5 3-6 3.5
4.2 5 4-3 4.5 2-5 2.5 3-1 5.54-3 9 4-3 4.5
0.9mm
2-3 3
1-1 2.75
2-6 3.5
3-2 4.5
4-3 6
1.6mm
3.0mm
5.0mm
8.0mm
100%CO2* 100%Argon*
InnershieldÆ
-FCAW
77%Argon23%CO2*
SuperGlazeÆ
4043,5356
UltraMagÆ
S6/EasyMIGôS6
100%CO2* 100%Argon*
NoGasRequired
NoGas
Required
InnershieldÆ-
FCAWNR211MP,
NR212DC-
OutershieldÆ-
71-CX,FCAW
DC+
CONSUMABLE PARTS
LINC GUN LG240G (REDI-MIG PLUS 255S)
Contact Tip M6 0.6mm LG240G KP10440-06
Contact Tip M6 0.8mm LG240G KP10440-08
Contact Tip M6 0.9mm LG240G KP10440-09
Contact Tip M6 1.2mm LG240G KP10440-12
Contact Tip M6 0.9mm Alum LG240G KP10441-09A
Contact Tip M6 1.0mm Alum LG240G KP10441-10A
Contact Tip M6 1.2mm Alum LG240G KP10441-12A
Nozzle 12mm LG240G KP10461-4
Tip Holder M6 LG240G KP10455-1
Gas Diffuser LG240G KP10404-WT
Liner 0.8-1.0mm 4m LG240G KP10413-4M
Liner 1.0-1.2mm 4m LG240G KP10414-4M
Liner 1.2-1.6mm 4m LG240G KP10415-4M
Liner 0.8-1.0mm 4m Teяon LG240G KP10422-4M
Liner 1.0-1.2mm 4m Teяon LG240G KP10418-4M
DRIVE ROLLERS
Drive Roll Kit 0.6/0.8mm KP61240-12S
Drive Roll Kit 0.9/1.2mm KP61240-1S
Drive Roll Kit 1.2/1.6mm KP61240-16
Drive Roll Kit 1.6/2.0mm KP61240-20
Drive Roll Kit 1.0/1.2mm Alum KP61240-1A
Drive Roll Kit 0.9/1.2mm FCW KP61240-12R
Drive Roll Kit 1.2/1.6mm FCW KP61240-16R
Drive Roll Kit 1.6/2.0mm FCW KP61240-20R
SuggestedsettingforweldingwiththeREDI-MIGÆ
PLUS255S
N/A = Not applicable
N/R = Not Recommended
IM6016 REDI-MIG®Plus215C,255C,255S Page15
REDI-MIG4s–Putinto2TSteptriggermode
Selecttheoutputvoltagerequiredtosuitthejobbysetting
therotaryvoltageswitches.(RefertoREDI-MIG®Welding
Guideforsuggestedsettings).
Before beginning welding, ensure the wire protrudes
from the gun tip by approximately 10-15mm. Ensure gas
is turned on for gas shielded processes. Ensure welding
shield and other protective clothing are in place. Present
theprotrudingelectrodejustoffthework.Maintainasteady
grip on the gun, protect your eyes with a welding shield,
thenpressandholdtheguntriggertocreatethearc.
If itisnecessarytoadjust theweld voltage,stop welding
beforechangingtherotaryvoltageswitches.
Adjustthewirefeedspeedasnecessarytosuitthejob.At
thecompletionoftheweld,releasetheguntriggerandhold
thegunovertheweldpooltostopthearc.
4TSteptriggermodeshouldonlybeused forlongwelds
byexperiencedoperators.
4.1 Changing Electrode Size and Type
Whenchangingtheelectrodesizeortype,ensurethewire
feeddriverollisthecorrectsizeandtypefortheelectrode.
Wire feed drive rolls have two grooves each of different
sizes.Ensuretherollislocatedbythekey.
When changing to aluminium welding a new drive roll,
cablelinerandcontacttipshouldbeused.
When changing to cored wire welding, a new drive roll
shouldbeused.
Alsocheck electrodepolarity,as differentprocessesmay
requiredifferentpolarities.
Note: Ensure that the correct gun liner and contact tip
are used for different wire sizes and processes. Change
gun 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 wire
to unravel. The spool hub should be tensioned so that
it neither drags nor overruns. The tension can be set by
adjustingthelargenutinsidethehubwithatubespanner.
Section 4 - WELDING
When the gun trigger is pressed (2T mode on REDI-MIG
4s) or pressed and released the first time (4T mode on
REDI-MIG 4s), the wire is at welding voltage. The wire
shouldnevertouchthecaseofthewirefeeder.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.Thefollowingpageswillhelpthe
inexperiencedoperatortounderstandweldinganddevelop
thisskill.
5.1 The Arc-Welding Circuit
Theoperators knowledgeofarc weldingmustgobeyond
thearc itself.Theoperator mustknow howtocontrol the
arc, and this requires a knowledge of the welding circuit
andtheequipmentthatprovidestheelectriccurrentusedin
thearc.Thecircuitbeginswheretheguncableisattached
to the welding machine. Current flows through the gun
cable,gun,andcontacttip,tothewireandacrossthearc.
Ontheworksideofthearc,currentflowsthroughthebase
metaltotheworkcableandbacktotheweldingmachine.
Thiscircuitmustbecompleteforthecurrenttoflow.
Thismachine’s weldingcircuithasavoltage outputof45
volts DC maximum. This voltage is quite low and is only
presentwhentheguntriggerisdepressed.
Toweld,theworkclampmustbetightlyconnectedtoclean
basemetal.Removepaint,rust,dirtoroilasnecessaryand
connecttheworkclampascloseaspossibletotheareayou
wishtoweld.Thishelpspreventcurrentfromgoingthrough
anunwantedpath.Avoidallowingtheweldingcircuittopass
throughhinges,bearings,electroniccomponents,orsimilar
devicesthatcanbedamaged.Alwaysdisconnectelectrical
devicesbeforeweldinguponthem.
Fumesandslaggeneratedfromelectrodesrecommended
forusewiththisweldingmachinecanbetoxic.
• Avoidcontactwitheyesandskin.
• Donottakeinternally.
• Keepoutofreachofchildren.
• Followallsafetyprecautionsfoundinthisoperating
manual.
The gun and cable assembly is held by the operator
who guides the automatically fed wire along the joint,
maintainingacontacttiptoworkdistanceofabout10-12
mmThisiscalledelectricalstickout.Thiselectricalstickout
(ESO) must be properly maintained by the operator. The
electricarcismadeinthegapbetweentheworkandthe
tipendofasmalldiameterwire.Whenthepowersourceis
properlyset,thearcgapismaintainedautomatically.
Arc welding is a manual skill requiring a steady hand,
goodphysicalcondition,andgoodeyesight.Theoperator
controlstheweldingarc,and,therefore,thequalityofthe
weldmade.
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 self
shieldedgaslessFCAW weldingarc.Itcloselyresembles
whatisactuallyseenwhilewelding.
The“arcstream”isseeninthemiddleofthepicture.This
is the electric arc created by the electric current flowing
throughthe spacebetween theend ofthe wireelectrode
andthe basemetal. Thetemperature ofthis arcis about
3300°C,whichismorethanenoughtomeltmetal.
Thearcisverybright,aswellashot,andcannotbelooked
at with the naked eye without risking painful injury. The
verydarklens, specificallydesignedforarc weldingmust
beusedwiththehandorfaceshieldwheneverviewingthe
arc.
Thearcmeltsthebasemetalandactuallydigsintoitmuch
aswaterthroughanozzleonagardenhosedigsintothe
earth.Themoltenmetalformsamoltenpoolorcraterand
tendstoflowawayfromthearc.Asitmovesawayfromthe
arc,itcoolsandsolidifies.
The function of the cored wire electrode is much more
than simply to carry current to the arc. The wire core is
composed of fluxes and/or alloying ingredients around
whichasteelsheathhasbeenformed.Itissimplyastick
electrode turned inside out in a continuous wire form.
Thecoredwiremeltsinthearcandtinydropletsofmolten
metalshootacrossthearcintothemoltenpool.Thewire
sheathprovidesadditionalfillermetalforthejointtofillthe
grooveorgapbetweenthetwopiecesofbasemetal.
Thecorematerialsalsomeltorburninthearcandperform
several functions. They make the arc steadier, provide a
shield of smoke-like gas around the arc to keep oxygen
and nitrogen in the air away from the molten metal, and
provide a flux for the molten pool. The flux picks up
impuritiesandformstheprotectiveslagontopoftheweld
duringcooling.
After running a weld bead, the slag may be removed
with a chipping hammer and wire brush. This improves
appearanceandallowsforinspectionofthefinishedweld.
Machinesizeandoutputcharacteristicslimit thesizeand
typeofwireelectrodewhichcanbeused.
5.3 The GMAW (MIG) Welding Arc (DC+)
Figure 2 illustrates the GMAW (MIG) welding arc. Solid
wiredoesnotcontainfluxesoringredientstoformitsown
shieldingandnoslagformstoprotectthemoltenweldmetal.
Forthisreason,acontinuousevenflowofshieldinggasis
neededtoprotectthemoltenweldmetalfromatmospheric
contaminantssuchasoxygenandnitrogen.Shieldinggas
is supplied through the gun and cable assembly, through
thegasnozzleandintotheweldingzone.
When comparing the GMAW and FCAW processes, you
canseethattheprincipaldifferencebetweenthetwoliesin
thetypeofshieldingused.GMAWusesgasforshielding,
thus we have Gas Metal Arc Welding. FCAW uses the
meltingorburningofthecoreingredientsforshielding,and
isthustermedSelf-ShieldedFluxCoredArcWelding.
Gas Metal Arc Welding (MIG) is capable of welding a
wide range of mild steels in all positions, however, more
skillisrequiredforout-of-positionweldingwiththeGMAW
process.
5.4 Process Selection
Bygainingknowledgeofthedifferences betweenthetwo
processes, you will be able to select the best process
forthe jobyouhave athand. Inselectinga process,you
shouldconsider:
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.Ifyouhaveanswered
notoanyoftheabovequestions,thenyoushouldconsider
usingtheFCAWprocess.
ForFCAW(Innershield)Process
1. DoIwantsimplicityandportability?
2. Will welding be performed outdoors or under windy
conditions?
3. DoIrequiregoodallpositionweldingcapability?
5.5 Common Metals
Most metals found around the farm, small shop or home
are low carbon steel, sometimes referred to as mild
steel. Typical items made with this type of steel include
most sheet metal, plate, pipe and rolled shapes such as
channels and angle irons. This type of steel can usually
beeasilyweldedwithoutspecialprecautions.Somesteels,
however,containhighercarbonlevelsorotheralloysand
are more difficult to weld. Basically, if a magnet sticks
to the metal and you can easily cut the metal with a file,
chancesaregoodthatthemetalismildsteelandthatyou
will be able to weld the material. In addition, aluminum
andstainlesssteelcanbeweldedusingtheanaluminum
welding kit. For further information on identifying various
typesofsteelsandothermetals,andforproperprocedures
forweldingthem,wesuggestyoupurchaseacopyof“New
LessonsinArcWelding”.
Regardlessofthetypeofmetal beingwelded, inorderto
getaqualityweld,itisimportantthatthemetalisfreeofoil,
paint,rustorothercontaminants.
5.6 Machine Set up for the Self-Shielded
(Gasless) FCAW Process
1. Ensurethemachinehasthecorrectdriverollandparts.
2. See the Welding Procedure Guide on the inside of wire
feedsectiondoorforinformationonsettingthecontrols.
3. Setthe“Voltage”and“WireSpeed”controlstothesettings
suggestedontheWeldingProcedureGuideforthewelding
wireandbasemetalthicknessbeingused.
4. Check that the polarity is correct for the welding wire
beingused.See Section1.5 forinstructions on changing
polarity.
5. Connect work clamp to metal to be welded. Work clamp
must make good electrical contact to the work piece.
The work piece must also be grounded as stated in the
“ArcWelding SafetyPrecautions” atthe beginningof this
manual.
Burningofcorematerials
inside wire electrode
resultsinshieldofgas.
ArcStream
CoredWire
ProtectiveSlag
WeldMetal
Figure1
Gasnozzle
Shieldinggas
Solidwire
electrode
Figure2
IM6016 REDI-MIG®Plus215C,255C,255S Page17
5.7 Welding Techniques For The Self-Shielded
(Gasless) FCAW Process
Foursimplemanipulationsare ofprime importancewhen
welding.Withcompletemasteryofthefour,weldingwillbe
easy.Theyareasfollows:
1. TheCorrectWeldingPosition
Figure 3 illustrates the correct welding position for
right handed people. (For left handed people, it is the
opposite.)
Holdthe gun(of thegunandcableassembly) inyour
righthandandholdtheshieldwithyourlefthand.(Left
handerssimplydotheopposite.)
WhenusingtheFCAWProcess,weldfromlefttoright
(if you are right handed). This enables you to clearly
seewhatyouaredoing.(Lefthandersdotheopposite.)
Tilt the gun toward the direction of travel holding the
electrodeatanangleasshowninFigure3.
When using an open arc process, it is necessary to use
correcteye,headandbodyprotection.
Protectyourself andothers,read “ARCRAYS canburn”at
thefrontofthismanual.
2. TheCorrectWayToStrikeAnArc
1. Be sure the work clamp makes good electrical
contacttothework.
2. Position gun over joint. End of wire may be lightly
touchingthework.
3. Positionfaceshieldtoprotectfaceandeyes,close
guntrigger,andbeginwelding.Holdthegunsothat
the contact tip to work distance is about 10 - 12
mm.
4. Tostopwelding,releasetheguntriggerandpullthe
gunawayfromtheworkafterthearcgoesout.
5. Aballmayformatthetipendofthewireafterwelding.
For easier restrikes the ball may be removed by
feedingoutafewinchesofwireandsimplybending
thewirebackandforthuntilitbreaksoff.
6. When no more welding is to be done, turn off the
machine.
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 ESO
shouldbeapproximately10-12mmlong.
The easiest way to tell whether the ESO is the correct length
is by listening to its sound. The correct ESO has a distinctive
“crackling” sound, very much like eggs frying in a pan. A long
ESO has a hollow, blowing or hissing sound. If the ESO is too
short,youmaystickthecontacttipornozzletotheweldpuddle
and/orfusethewiretothecontacttip.
4. TheCorrectWeldingSpeed
Theimportantthingtowatchwhileweldingisthepuddle
ofmoltenmetalrightbehindthearc.SeeFigure5.Do
not watch the arc itself. It is the appearance of the
puddleandtheridgewherethemoltenpuddlesolidifies
thatindicatescorrectweldingspeed. Theridgeshould
beapproximately10mmbehindthewireelectrode.
Mostbeginnerstendtoweldtoofast,resultinginathin
uneven,“wormy” lookingbead.Theyarenot watching
themoltenmetal.
HelpfulHints
1. For general welding, it is not necessary to weave the
arc, neither forward or backward nor sideways. Weld
alongatasteadypace.Youwillfinditeasier.
2. When welding on thin plate, you will find that you will
have to increase the welding speed, whereas when
welding on heavy plate, it is necessary to go more
slowlyinordertogetgoodpenetration.
3. When welding sheet metal 1.6 mm and lighter, heat
buildup may cause part warpage and burn through.
One way to eliminate these problems is to use the
back-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
10-12mm
ElectricalStickout
(ESO)
ContactTip
WireElectrode
Figure4
Solidifyingridge
Moltenpuddle
Figure5
FirstweldfromAtoB;thenfromCtoA;then
fromDtoC;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 12 mm and the gun is at proper
angle.
4. After you strike the arc, practice the correct electrical
stickout.Learntodistinguishitbyitssound.
5. Whenyouaresurethatyoucanholdthecorrectelectrical
stickout,withasmooth“crackling”arcstartmoving.Lookat
themoltenpuddleconstantly,andlookatthe“ridge”where
themetalsolidifies.
6. Run beads on a flat plate. Run them parallel to the top
edge (the edge farthest away from you). This gives you
practice in running straight welds, and also gives you
an easy way to check your progress. The 10th weld will
lookconsiderablybetter thanthefirstweld.Byconstantly
checkingonyourmistakesandyourprogress,weldingwill
soonbeamatterofroutine.
5.8 Machine Set Up for the GMAW (MIG) Process
and Gas Shielded GCAW Processes
1. The REDI-MIG® Plus comes ready for welding using the
MIGprocess.
2. See the Procedure Welding Guide on the inside of wire
feedsectiondoorforinformationonsettingthecontrols.
3. Setthe“Voltage”and“WireSpeed”controlstothesettings
suggestedontheProcedureWeldingGuideforthewelding
wireandbasemetalthicknessbeingused.’
4. Checkthatthepolarityiscorrectfortheweldingwirebeing
used. Set the polarity for DC(+) when welding with the
GMAW(MIG)process.SeeSection1.5forinstructionsfor
changingpolarity.
5. Checkthatthegasnozzleandpropersizelinerandcontact
tiparebeingusedandthatthegassupplyisturnedon.Set
for7to10L/min.undernormalconditions,increasetoas
highas17L/min.underdrafty(slightlywindy)conditions.
6. Connect work clamp to metal to be welded. Work clamp
must make good electrical contact to the work piece.
The work piece must also be grounded as stated in the
“ArcWelding SafetyPrecautions” atthe beginningof this
manual.
5.9 Welding Techniques for the GMAW (MIG)
Process
Foursimplemanipulationsare ofprime importancewhen
welding.Withcompletemasteryofthefour,weldingwillbe
easy.Theyareasfollows:
1. TheCorrectWeldingPosition
Figure 8 illustrates the correct welding position for
right handed people. (For left handed people, it is the
opposite.)
When GMAW (MIG) welding on sheet metal, it is
importanttousethe“forehand”pushtechnique.
Holdthe gun(of thegunandcableassembly) inyour
righthandandholdtheshieldwithyourlefthand.(Left
handerssimplydotheopposite.)Weldfromrighttoleft
(ifyou arerighthanded). Thisresultsin acolderweld
andhaslesstendencyforburnthrough.
When using an open arc process, it Is necessary to use
correcteye,headandbodyprotection.
Protectyourself andothers,read “ARCRAYS canburn”at
thefrontofthismanual.
2. TheCorrectWayToStrikeAnArc
1. Be sure the work clamp makes good electrical
contacttothework.
2. Position gun over joint. End of wire may be lightly
touchingthework.
3. Positionfaceshieldtoprotectfaceandeyes,close
guntrigger,andbeginwelding.Holdthegunsothat
the contact tip to work distance is about 10 - 12
mm.
4. Tostopwelding,releasetheguntriggerandpullthe
gunawayfromtheworkafterthearcgoesout.
5. A ball may form at the tip end of the wire after
welding. For easier restrikes, the ball may be
removed by feeding out a few inches of wire and
cuttingofftheendofthewirewithwirecutters.
6. When no more welding is to be done, close the
valveon thegas cylinder,momentarily operatethe
guntriggertoreleasegaspressure,thenturnoffthe
machine.
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.SeeFigure
9.
Once the arc has been established, maintaining the
correct ESO becomes extremely important. The ESO
shouldbeapproximately10to12mmlong.
TheeasiestwaytotellwhethertheESOisthecorrect
lengthisbylisteningtoitssound.ThecorrectESOhas
a distinctive “crackling” sound, very much like eggs
frying in a pan. A long ESO has a hollow, blowing or
hissingsound.IftheESOistooshort,youmaystickthe
contacttipornozzletotheweldpuddleand/orfusethe
wiretothecontacttip.
4. TheCorrectWeldingSpeed
Theimportantthingtowatchwhileweldingisthepuddle
of molten metal right behind the arc. See Figure 10.
Donotwatchthearcitself.Itistheappearanceofthe
puddleandtheridgewherethemoltenpuddlesolidifies
thatindicatescorrectweldingspeed. Theridgeshould
beapproximately10mmbehindthewireelectrode.
Mostbeginnerstendtoweldtoofast,resultinginathin,
uneven,“wormy” lookingbead.Theyarenot watching
themoltenmetal.
HelpfulHints
1. For general welding, it is not necessary to weave the
arc, neither forward or backward nor sideways. Weld
alongatasteadypace.Youwillfinditeasier.
2. When welding on thin plate, you will find that you will
have to increase the welding speed, whereas when
welding on heavy plate, it is necessary to go more
slowlyinordertogetgoodpenetration.
3. When welding sheet metal 1.6mm and lighter, heat
buildup may cause part warpage and burn through.
One way to eliminate these problems is to use the
back-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 to strike an arc by positioning the gun over the
jointandtouchingthewiretothework.
2. Positionfaceshieldtoprotectfaceandeyes.
3. Depress gun trigger, hold gun so contact tip to work
distance Is about 10-12 mm and the gun is at proper
angle.
4. After you strike the arc, practice the correct electrical
stickout.Learntodistinguishitbyitssound.
5. Whenyouaresurethatyoucanholdthecorrectelectrical
stickout,withasmooth“crackling”arc,startmoving.Look
atthemoltenpuddleconstantly,
6. Run beads on a flat plate. Run them parallel to the top
edge (the edge farthest away from you). This gives you
practice in running straight welds, and also gives you
an easy way to check your progress. The 10th weld will
lookconsiderablybetter thanthefirstweld.Byconstantly
checkingonyourmistakesandyourprogress,weldingwill
soonbeamatterofroutine.
5.10 Joint Types and Positions
Fivetypes ofweldingjointsare: ButtWelds,FilletWelds,
LapWelds,EdgeWeldsandCornerWelds.SeeFigure10.
Ofthese,the ButtWeldandFilletWeldarethetwomost
commonwelds.
5.11 Butt Welds
Placetwoplatessidebyside,leavingaspaceapproximately
onehalfthethicknessofthemetalbetweentheminorder
togetdeeperpenetration.
Securely clamp or tack weld the plates at both ends,
otherwisetheheatwillcausetheplatestomoveapart.See
Figure11.
Now weldthe twoplates together.Weld from leftto right
(if right handed and using self-shielded FCAW process).
Pointthewireelectrodedowninthecrackbetweenthetwo
plates,keepingthegunslightlytiltedinthedirectionoftravel.
Watchthemoltenmetaltobesureitdistributesitselfevenly
onbothedgesandinbetweentheplates.
5.12 Penetration
Unlessabuttweldpenetratescloseto100%ofthemetal
thickness, a butt weld will be weaker than the material
weldedtogether.In theexample shownin Figure12, the
totalweldisonlyhalfthethicknessofthematerialthusthe
weldisonlyapproximatelyhalfasstrongasthemetal.
In the example shown in Figure 13, the joint has been
weldedsothat 100%penetrationcouldbeachieved. The
weld,ifproperlymade,isasstrongasorstrongerthanthe
originalmetal.
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
When weldingfillet welds,it isvery important tohold the
wireelectrodeata45°anglebetweenthetwosidesorthe
metal will not distribute itself evenly. The gun nozzle is
generallyformedatanangletofacilitatethis.SeeFigure14.
5.14 Welding In The Vertical Position
Welding in the vertical position can be done either
vertical-upor vertical-down.Vertical-upisusedwhenever
a larger, stronger weld is desired. Vertical-down is used
primarily on sheet metal 4.0mm and under for fast, low
penetratingwelds.
5.15 Vertical-up And Overhead Welding
Theproblem,whenweldingvertical-up,istoputthemolten
metalwhereitiswantedandmakeitstaythere.Iftoomuch
molten metal is deposited, gravity will pull it downwards
andmakeit“drip”.Therefore,acertaintechniquehastobe
followed.
When welding out-of-position, run stringer beads. Don’t
whip,breakthearc,moveoutofthepuddle,ormovetoo
fastin anydirection.Use WireFeed Speed(WFS)in the
lowportionoftherange.Thegeneraltechniqueandproper
gunangleareillustratedinFigure15.
Generally,keeptheelectrode nearlyperpendicular tothe
jointasillustrated.Themaximumangleaboveperpendicular
mayberequiredifporositybecomesaproblem.
5.16 Vertical-down Welding
RefertoFigure16Vertical-downweldsareappliedatafast
pace.Theseweldsarethereforeshallowandnarrowand,
assuch,areexcellentforsheetmetal.Vertical-downwelds
maybeappliedto4.0mmandlightermaterial.
Usestringerbeadsandtiptheguninthedirectionoftravel
so the arc force helps hold the molten metal in the joint.
Move as fast as possible consistent with desired bead
shape.
Theimportantthingistocontinueloweringtheentirearm
as the weld is made so the angle of the gun does not
change.Movetheelectrodewirefastenoughthattheslag
doesnotcatchupwiththearc.Vertical-downweldinggives
thin,shallowwelds.Itshouldnotbeusedonheavymaterial
wherelargeweldsarerequired.
5.17 Troubleshooting Welds
Goodweldshaveexcellentappearance.
ToEliminatePorosity(inorderofimportance):
1. Turnongassupply,ifused
2. Decreasevoltage.
3. Increasestickout.
4. IncreaseWFS(wirefeedspeed).
5. Decreasetorchangle.
6. Decreasetravelspeed.
Note: Always be sure the joint is free from moisture, 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 thicker materials than recommended
mayresultinpoorwelds.Theweldsmay“look”good,but
may 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
Propergun
angleforFCAW
processwelding
intheverticalup
position.
Propergun
angleforGMAW
processwelding
intheverticalup
position.
Figure16
Figure15
This manual suits for next models
2
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