Lincoln Electric REDI-MIG 455 Remote Operating Manual
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Lincoln Electric REDI-MIG 455 Remote Operating Manual

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Semi Automatic Arc Welding Machine
This manual applies to
Part No.
Code
Description
KA1443-2
F948
REDI-MIG 455
Remote
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.
IMA 603
OPERATING MANUAL
REDI-MIG 455 Remote
Volts
415
SAFETY DEPENDS ON YOU
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS
ACN 000 040 308
A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
REDI-MIG 455 Remote
IMA 603
EMC Compliant
Page

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Summary of Contents for Lincoln Electric REDI-MIG 455 Remote

  • Page 1 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: Electric Shock Can Kill

    This can create fire hazards or including the material safety data sheet (MSDS) and overheat lifting chains or cables until they fail. follow your employer’s safety practices. h. Also see Item 7c. e. Also see Item 7b. Page 2 REDI-MIG 455 Remote IMA 603...
  • 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 That welder and his or her pacemaker may be quite practice to eliminate a common problem on welding - a different from you and your pacemaker. poor work connection. • Do not work next to the welding power source. Page 4 REDI-MIG 455 Remote IMA 603...

  • Page 5: Assessment Of Area

    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 as filtering the mains supply. Consideration should be given to •...
  • 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 Examine Carton and Equipment for Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.

  • Page 7: Table Of Contents

    ACCESSORIES Section 8 GROUND TEST PROCEDURE Section 9 TROUBLESHOOTING PARTS LIST REDI-MIG 455 Remote WIRING DIAGRAM REDI-MIG 455 Remote PARTS LISTS REDI-MIG 4D Remote Wire Feeder WIRING DIAGRAM REDI-MIG 4D Remote Wire Feeder WIRE DRIVE ASSEMBLY PARTS LISTS REDI-MIG 2 & 4 TORCHES...

  • Page 8: Installation

    PRODUCT DESCRIPTION The REDI-MIG 455 Remote offers a remote wire feeder and a separate Constant Voltage DC arc welding machine. It combines a solid state power source with electronically controlled wire feeding equipment. Excellent arc characteristics are provided for both gas shielded and self shielded welding within its current range.

  • Page 9: Gun And Cable Installation

    REDI-MIG 455 Remote Power Source eg. for electrode (- )ve, connect the electrode cable to the (-)ve output connection.

  • Page 10: Operating Instructions

    Connection. cooling fan operative.) The Low Inductance Negative Output Connection is symbolised by “ “. The Low Inductance Negative Output Connection is more suitable when a crisp arc is preferred. Page 10 REDI-MIG 455 Remote IMA 603...

  • Page 11: Setting Up For Welding

    Connection and diagrams below. Gas Shielded Wires Gasless Wires SETUP SETUP Negative Output Stud Positive Output Stud Negative Output Stud Positive Output Stud Work Lead To Wire Feeder To Wire Feeder Work Lead IMA 603 REDI-MIG 455 Remote Page 11...
  • Page 12 Page 12 REDI-MIG 455 Remote IMA 603...

  • Page 13: Welding

    Cored Wire 4 Step trigger mode should only be used for long welds by experienced operators. * Standard on REDI-MIG 455 Remote. 4.1 Changing Electrode Size and Type 4.2 Adjusting Spool Tension When changing the electrode size or type, ensure the wire The spool should stop rotating when the wire feed roll feed drive roll is the correct size and type for the electrode.

  • Page 14: The Self-Shielded (Gasless) Fcaw Welding Arc

    Connect work clamp to metal to be welded. Work clamp electrode must make good electrical contact to the work piece. The work piece must also be grounded as stated in the “Arc Welding Safety Precautions” at the beginning of this manual. Page 14 REDI-MIG 455 Remote IMA 603...

  • Page 15: Welding Techniques For The Self-Shielded (Gasless) Fcaw Process

    Once the arc has been established, maintaining the exercise. correct ESO becomes extremely important. The ESO should be approximately 10 - 12 mm long. Figure 4 Contact Tip Wire Electrode 10 - 12 mm Electrical Stickout (ESO) IMA 603 REDI-MIG 455 Remote Page 15...

  • Page 16: Welding Techniques For The Gmaw (Mig) Process

    The REDI-MIG 455 Remote comes ready for welding using 6. When no more welding is to be done, close the valve the MIG process.

  • Page 17: Joint Types And Positions

    2. Correct way to strike an arc 3. Correct electrical stickout 4. Correct welding speed is to perform the following exercise. Refer to Figure 4. For the REDI-MIG 455 Remote, use the following: 5.12 Penetration Mild Steel Sheet (1.6 mm) Electrode 0.9mm L54/L56 Ultra...

  • Page 18: Fillet Welds

    Use stringer beads and tip the gun in the direction of travel 6. Check for correct gas, if used. so the arc force helps hold the molten metal in the joint. Move as fast as possible consistent with desired bead shape. Page 18 REDI-MIG 455 Remote IMA 603...

  • Page 19: Maintenance

    All drive rolls are stamped with the wire sizes they will feed. If a wire size other than that stamped on the roll is to be The REDI-MIG 455 Remote has built-in protective used, the drive roll must be changed.

  • Page 20: Liner Removal, Installation And Trimming Instructions For Redi-Mig 4 Torch

    PCB in counter-clockwise to minimum acceleration when fully clockwise. the REDI-MIG 4D Remote Wire Feeder. This is particularly important when welding aluminium wire. The factory setting is fully clockwise. Page 20 REDI-MIG 455 Remote IMA 603...

  • Page 21: Troubleshooting

    Do not exceed current and duty cycle rating of Tip overheating due to prolonged or gun. excessive high current and/or duty cycle welding. A light application of high temperature antiseize lubricant may be applied to tip threads. IMA 603 REDI-MIG 455 Remote Page 21...
  • Page 22 Faulty switch either coarse control (on/off) Replace switch. or fine control. Faulty pilot transformer. Replace. Faulty main transformer. Replace. Faulty rectifier. Replace Replace. Faulty choke. Check fuses, check input connection. One phase disconnected. Page 22 REDI-MIG 455 Remote IMA 603...
  • Page 23 AP-207 Operative: Sep 2001 Supersedes: REDI-MIG 455 Remote KA1443-2 (415V) 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 24 AP-207C General Assembly Operative: Sep 2001 Supersedes: Page 24 REDI-MIG 455 Remote IMA 603...
  • Page 25 Wraparound assembly: Cover and hinge assembly M51398 Lock S21033 Right panel L50640 Left panel L50641 Top left panel L50662 Middle left panel L50664 Low left panel L50663 Door bumper T14882 Wire feeder mounting M12206 IMA 603 REDI-MIG 455 Remote Page 25...
  • Page 26 AP-207-D Front Panel Assembly Operative: Sep 2001 Supersedes: Page 26 REDI-MIG 455 Remote IMA 603...
  • Page 27 T51089 Output connector M13896-3 Screw S9225-8 Amphenol plug (4 contacts) S12021-18 Screw S8025-73 Louver G2016 Screw S8025-78 Mounting M51278 Digital display selector T10800-4 Meter Option Volt-ammeter PC board M51397-1 Shunt (Not shown) S51776-1 IMA 603 REDI-MIG 455 Remote Page 27...
  • Page 28 AP-207W Wiring Diagram Operative: March 2000 Supersedes: REDI-MIG 455 Remote Page 28 REDI-MIG 455 Remote IMA 603...
  • Page 29 Operating Manual ..............REDI-MIG 325 IMA 603 # Indicates a change this printing IMA 603 REDI-MIG 455 Remote Page 29...
  • Page 30 AP-56C Panel Assembly Operative: May 2001 Supersedes: N.B. 12 27 13 52 57 N.A. 10 12 39 50 AG 1412-1 (A14-4-00) Page 30 REDI-MIG 455 Remote IMA 603...
  • Page 31 Terminal .25 Tab 14-16ga S8053-134 ” x 1” T/C Screw ” Flatwasher ” Flatwasher ” Flatwasher 8ga x .32” Sems Screw T10082-27 Insulation T12792-1 SPDT Toggle Switch T13562 Fastener Button T14659-1 ” Internal Starwasher IMA 603 REDI-MIG 455 Remote Page 31...
  • Page 32 NOTES Page 32 REDI-MIG 455 Remote IMA 603...
  • Page 33 AP- 56W Wiring Diagram Operative: May 2001 Supersedes: 4D Remote IMA 603 REDI-MIG 455 Remote Page 33...

  • Page 34: Wire Drive Assembly

    AP-56-D Wire Drive Assembly Operative: Supersedes: 5,6,7,8 10,11,12 Page 34 REDI-MIG 455 Remote IMA 603...
  • Page 35 OPTIONAL DRIVE ROLLS 0.8-0.9mm Solid Steel AS4449-11 0.9-1.2mm Solid Steel AS4449-8 1.0-1.2mm Solid Steel AS4449-2 0.8-1.0mm Aluminium AS4449-5 0.9-1.2mm Aluminium AS4449-12 0.8-1.0mm Flux Cored AS4449-3 0.9-1.2mm Flux Cored AS4449-13 1.2-1.6mm Flux Cored AS4449-4 IMA 603 REDI-MIG 455 Remote Page 35...
  • Page 36 AP-49C REDI-MIG Torch 2 & 4 Consumables Operative: May 2001 Supersedes: REDI-MIG Torch 2 & 4 Assembly Page 36 REDI-MIG 455 Remote IMA 603...
  • Page 37 Steel Liner 0.9-1.2 GM826 QY44-3545-15 Steel Liner 1.0-1.2 GM12 QY42-4045-15 Steel Liner 1.0-1.2 QY44-4045-15 1 Steel Liner 1.2-1.6 GM13 QY44-116-15 Steel Liner 1.6-2.0 QY44-56Y-15 Teflon Liner 0.9-1.2 GM230 QY42N-3545-15 Teflon Liner 1.2-1.6 GM231 QY44N-116-15 IMA 603 REDI-MIG 455 Remote Page 37...

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