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REDI-MIG 255 Integrated
REDI-MIG 255 Remote
Semi Automatic Arc Welding Machine
Part No.
Description
KA1432-1
REDI-MIG 255i
KA1432-11
REDI-MIG 255i
KA1432-2
REDI-MIG 255R
KA1432-12
REDI-MIG 255R
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.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS
OPERATING MANUAL
for codes 70037 and above
Input Volts
240
220
240
220
SAFETY DEPENDS ON YOU
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
A.B.N. 36 000 040 308
IMA 598B
February 2004
EMC Compliant
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Summary of Contents for Lincoln Electric REDI-MIG 255 Integrated
- Page 1 EMC Compliant 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.
- Page 2 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 ARC RAYS can burn ELECTRIC SHOCK can kill 1.
- Page 3 3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric. 4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory”...
- Page 4 WELDING, EMF & PACEMAKERS All welders should follow safe practices that minimise their Welders with pacemakers exposure to electric and magnetic fields (EMF). There is no question that the fields in arc welding can interfere For welders wearing implanted pacemakers, safe welding with a pacemakers function.
- Page 5 Welding equipment should be connected to the mains supply reproduced from British Standard EN 50199) according to the manufacturer’s recommendations.If interference • for using with other Lincoln Electric/LiquidArc equipment. occurs, it may be necessary to take additional precautions such • designed for industrial and professional use.
- Page 6 Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product - as much pride as we have in bringing this product to you! Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
- Page 7 Section 8 GROUND TEST PROCEDURE Section 9 TROUBLESHOOTING PARTS LISTS REDI-MIG 255 WIRING DIAGRAM REDI-MIG 255 Remote WIRING DIAGRAM REDI-MIG 255 Integrated PARTS LISTS REDI-MIG 4D Remote WIRING DIAGRAM REDI-MIG 4D Remote Wire Feeder WIRE DRIVE ASSEMBLY PARTS LISTS REDI-MIG 240 MIG GUN...
- Page 8 PRODUCT DESCRIPTION The REDI-MIG 255 Integrated is a fully integrated semi-automatic Constant Voltage DC arc welding machine. The REDI-MIG 255 Remote offers a remote wire feeder and a separate Constant Voltage DC arc welding machine. They combine a solid state power source with electronically controlled wire feeding equipment.
- Page 9 Turn the welder power switch off before changing polarity. Technical Note 7 available from the Welding Technology Institute of Australia. The REDI-MIG 255 Integrated is shipped from the factory connected electrode (+)ve. This is the normal polarity for Attach the regulator/flowmeter to the cylinder valve and gas shielded welding.
- Page 10 Section 2 - OPERATING INSTRUCTIONS 2.2 Control Panel WARNING • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. ELECTRIC • Always wear dry insulating SHOCK gloves. can kill •...
- Page 11 Burnback Control * Use this same toggle switch to operate the wire feed motor and “cold” inch the wire, by pushing the toggle switch This control is located below the output studs in the wire downwards. feed bay. The burnback control adjusts the time period from when the drive motor stops until the power source and gas 2 Step/4 Step Trigger Operation * solenoid are switched off.
- Page 12 Page REDI-MIG 255 IMA 598B...
- Page 13 Section 4 - WELDING the optional 1.2mm Aluminium Feeding Kit (KA1440-4 for WARNING the REDI-MIG 255 Integrated and KA1440-5 for the REDI- MIG 255 Remote). When the gun trigger is pressed (2 mode) or pressed and When changing to cored wire welding, a new drive roll released the first time (4 mode), the wire is at welding should be used.
- Page 14 5.2 The Self-Shielded (Gasless) When comparing the GMAW and FCAW processes, you can see that the principal difference between the two lies in FCAW Welding Arc (DC-) the type of shielding used. GMAW uses gas for shielding, thus we have Gas Metal Arc Welding. FCAW uses the Figure 1 illustrates the action taking place in the self melting or burning of the core ingredients for shielding, and shielded gasless FCAW welding arc.
- Page 15 5.7 Welding Techniques For The Self- Figure 4 Shielded (Gasless) FCAW Process Contact Tip Four simple manipulations are of prime importance when welding. With complete mastery of the four, welding will be easy. They are as follows: Wire Electrode 1. The Correct Welding Position 10 - 12 mm Electrical Stickout Figure 3 illustrates the correct welding position for right...
- Page 16 (For left handed people, it is the opposite.) When GMAW (MIG) welding on sheet metal, it is For the REDI-MIG 255 Integrated and Remote, use the following: important to use the “forehand” push technique. Mild Steel Plate 3.0mm...
- Page 17 5.12 Penetration Refer to Figure 4. For the REDI-MIG 255 Integrated and Remote, use the following: Unless a butt weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material Mild Steel Sheet (1.6 mm)
- Page 18 Figure 13 The important thing is to continue lowering the entire arm as the weld is made so the angle of the gun does not change. Move the electrode wire fast enough that the slag does not catch up with the arc. Vertical-down welding gives thin, shallow welds.
- Page 19 All drive rolls are stamped with the wire sizes they will feed. Welding Thermal Overload Protection If a wire size other than that stamped on the roll is to be The REDI-MIG 255 Integrated and Remote has built-in used, the drive roll must be changed. protective thermostats that respond to excessive Avoiding Wire Feeding Problems temperature.
- Page 20 PCB in This is particularly important when welding aluminium wire. The the REDI-MIG 255 Integrated power source of REDI-MIG 4D factory setting is fully clockwise. Remote Wire Feeder.
- Page 21 SECTION 9 - TROUBLESHOOTING WARNING • Have an electrician install and service this equipment. • Turn the input power off at the fuse box and unplug the machine before working on equipment. ELECTRIC • Do not touch electrically hot parts. SHOCK can kill Possible Cause...
- Page 22 TROUBLESHOOTING What To Do Problem Possible Cause No wire feed, although arc Defective wire feed motor or wire drive Measure the voltage between the motor voltage is present. control PC board. leads (54) and (53) when the Gas Purge/Wire Inch toggle switch is pressed downwards.
- Page 23 AP-206 Operative: Feb 2004 Supersedes: May 2001 REDI-MIG 255 Integrated KA1432-1 (240V) KA1432-11 (220V) REDI-MIG 255 Remote KA1432-2 (240V) KA1432-12 (220V) Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed.
- Page 24 AP- 206C Operative: Feb 2004 General Assembly Supersedes: Oct 1999 21 21a N.A. AG1417-2 and 6 (A16.8.00M) Integrated model shown Page 24 REDI-MIG 255 IMA 598B...
- Page 25 AP-206C2 Operative: Feb 2004 Supersedes: May 2001 v# Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the Recommended Spare Parts are highlighted in bold heading number called for in the model index page. Nut, bolt and washer sizes are given so they may be procured locally.
- Page 26 AP-206C2 Operative: 13.10.99 General Assembly Supersedes: N.E. AG1417-2 and 6 (A16.8.00M) Integrated model shown Page 26 REDI-MIG 255 IMA 598B...
- Page 27 AP-206C3 Operative: May 2001 Supersedes: v# Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the heading number called for in the model index page. Recommended Spare Parts are highlighted in bold Nut, bolt and washer sizes are given so they may be procured locally.
- Page 28 AP- 206D Operative: 13.10.99 Front Panel Assembly Supersedes: AL2683-2 (A13.10.99) Integrated model shown DETAIL A AM3391-8 Page 28 REDI-MIG 255 IMA 598B...
- Page 29 AP-206D1 Operative: May 2001 Supersedes: v# Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the heading number called for in the model index page. Recommended Spare Parts are highlighted in bold Nut, bolt and washer sizes are given so they may be procured locally.
- Page 30 AP- 58-E Cover Panels Operative: May 2001 Supersedes: N.A. N.A. Ref: AM3608 (A13-10-99) AP- 58-E1 Operative: May 2001 Supersedes: # Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the Recommended Spare Parts are highlighted in bold heading number called for in the model index page.
- Page 31 WIRING DIAGRAM AP-206W Operative: 13.10.99 Supersedes: REDI-MIG 255 Remote IMA 598B REDI-MIG 255 Page 31...
- Page 32 WIRING DIAGRAM AP-206W1 Operative: 13.10.99 Supersedes: REDI-MIG 255 Integrated Page 32 REDI-MIG 255 IMA 598B...
- Page 33 AP-56 Operative: Nov 2003 Supersedes: May 2001 REDI-MIG 4D Remote KA1435 Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed. Contact the Service Department for any COLUMN TO USE IN EACH PARTS LIST FOR EACH code numbers not listed.
- Page 34 AP-56C Panel Assembly Operative: Nov 2003 Supersedes: May 2001 AG 1412-1 (A14-4-00) Page 34 REDI-MIG 255 IMA 598B...
- Page 35 AP- 56-C1 Operative: Nov 2003 Supersedes: May 2001 # Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the heading number called for in the model index page. Recommended Spare Parts are highlighted in bold Nut, bolt and washer sizes are given so they may be procured locally.
- Page 36 NOTES Page 36 REDI-MIG 255 IMA 598B...
- Page 37 AP- 56W Wiring Diagram Operative: May 2001 Supersedes: 4D Remote IMA 598B REDI-MIG 255 Page 37...
- Page 38 AP-56-D Wire Drive Assembly Operative: Supersedes: 5,6,7,8 10,11,12 AM3391SP Page 38 REDI-MIG 255 IMA 598B...
- Page 39 AP-56-D1 Operative: Supersedes: # Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the heading number called for in the model index page. Recommended Spare Parts are highlighted in bold Nut, bolt and washer sizes are given so they may be procured locally.
- Page 40 AP-49D REDI-MIG 240 Operative: 4.7.03 Supersedes: MIG Gun Page 40 REDI-MIG 255 IMA 598B...
- Page 41 AP-49D.1 Operative: 4.7.03 Supersedes: # Indicates a change this printing. * Items not illustrated. Use only the parts marked “X” in the column under the Recommended Spare Parts are highlighted in bold heading number called for in the model index page. Nut, bolt and washer sizes are given so they may be procured locally.
- Page 42 NOTES Page 42 REDI-MIG 255 IMA 598B...
- Page 43 NOTES IMA 598B REDI-MIG 255 Page 43...
- Page 44 We respond to our customers based on the best information in our One Year* possession at that time. Lincoln Electric is not in a position to warrant or guarantee Ruggerini Engines and Accessories such advice and assumes no liability, with respect to such information or advice. We...