Welding; Changing Electrode Size And Type; Adjusting Spool Tension; Learning To Weld - Lincoln Electric REDI-MIG Plus 215C Operator's Manual

WARNING
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
should never touch the case of the wire feeder. If it does,
it is possible for the wire to arc to the case.
Any wire overrun should be avoided.
REDI-MIG 4s – Put into 2T Step trigger mode
S elect the output voltage required to suit the job by setting
the rotary voltage switches. (Refer to REDI-MIG
Guide for suggested settings).
B efore 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
the protruding electrode just off the work. Maintain a steady
grip on the gun, protect your eyes with a welding shield,
then press and hold the gun trigger to create the arc.
I f it is necessary to adjust the weld voltage, stop welding
before changing the rotary voltage switches.
A djust the wire feed speed as necessary to suit the job. At
the completion of the weld, release the gun trigger and hold
the gun over the weld pool to stop the arc.
4 T Step trigger mode should only be used for long welds
by experienced operators.

4.1 Changing Electrode Size and Type

W hen changing the electrode size or type, ensure the wire
feed drive roll is the correct size and type for the electrode.
Wire feed drive rolls have two grooves each of different
sizes. Ensure the roll is located by the key.
W hen changing to aluminium welding a new drive roll,
cable liner and contact tip should be used.
W hen changing to cored wire welding, a new drive roll
should be used.
N o one can learn to weld simply by reading about it. Skill
comes only with practice. The following pages will help the
inexperienced operator to understand welding and develop
this skill.

5.1 The Arc-Welding Circuit

T he operators knowledge of arc welding must go beyond
the arc itself. The operator must know how to control the
arc, and this requires a knowledge of the welding circuit
and the equipment that provides the electric current used in
the arc. The circuit begins where the gun cable is attached
to the welding machine. Current flows through the gun
cable, gun, and contact tip, to the wire and across the arc.
On the work side of the arc, current flows through the base
metal to the work cable and back to the welding machine.
This circuit must be complete for the current to flow.
T his machine's welding circuit has a voltage output of 45
volts DC maximum. This voltage is quite low and is only
present when the gun trigger is depressed.
T o weld, the work clamp must be tightly connected to clean
base metal. Remove paint, rust, dirt or oil as necessary and
connect the work clamp as close as possible to the area you
wish to weld. This helps prevent current from going through
an unwanted path. Avoid allowing the welding circuit to pass
through hinges, bearings, electronic components, or similar
devices that can be damaged. Always disconnect electrical
devices before welding upon them.
IM6016
Section 4 - WELDING

Welding

®
Section 5 - LEARNING TO WELD
REDI-MIG Plus 215C, 255C, 255S
®
A lso check electrode polarity, as different processes may
require different polarities.
N ote: 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,
Installation and Trimming Instructions for LINC Gun
360 MIG guns.
Available Drive Rolls
Material No. Size (mm) Used With For Use With
KP61015-08 0.6/0.8
KP61015-09 0.8/0.9
KP61015-0912 0.9/1.2
KP61015-0912A 0.9/1.2
KP61015-12 1.0/1.2
KP61015-0912R 0.9/1.2
KP61015-16R 1.2/1.6
KP61240-08 0.6/0.8
KP61240-0912 0.9/1.2
KP61240-16 1.2/1.6
KP61240-0912A 0.9/1.2
KP61240-12A 1.0/1.2
KP61240-0912R 0.9/1.2
KP61240-16R 1.2/1.6

4.2 Adjusting Spool Tension

T he 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
adjusting the large nut inside the hub with a tube spanner.
FUMES AND GASES
can be dangerous
Fumes and slag generated from electrodes recommended
for use with this welding machine can be toxic.
• Avoid contact with eyes and skin.
• Do not take internally.
• Keep out of reach of children.
• F ollow all safety precautions found in this operating
manual.
T he gun and cable assembly is held by the operator
who guides the automatically fed wire along the joint,
maintaining a contact tip to work distance of about 10 - 12
mm This is called electrical stickout. This electrical stickout
(ESO) must be properly maintained by the operator. The
electric arc is made in the gap between the work and the
tip end of a small diameter wire. When the power source is
properly set, the arc gap is maintained automatically.
A rc welding is a manual skill requiring a steady hand,
good physical condition, and good eyesight. The operator
controls the welding arc, and, therefore, the quality of the
weld made.
®
Solid Redimig Plus 215/255C
®
Solid Redimig Plus 215/255C
®
Solid Redimig Plus 215/255C
®
Aluminium Redimig Plus 215/255C
®
Solid Redimig Plus 215/255C
®
Cored Redimig Plus 215/255C
®
Cored Redimig Plus 215/255C
®
Solid Redimig Plus 255S
®
Solid Redimig Plus 255S
®
Solid Redimig Plus 255S
®
Aluminium Redimig Plus 255S
®
Aluminium Redimig Plus 255S
®
Cored Redimig Plus 255S
®
Cored Redimig Plus 255S
®
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