Lincoln Electric REDI-MIG 205 Integrated Operating Manual
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Lincoln Electric REDI-MIG 205 Integrated Operating Manual

Lincoln Electric REDI-MIG 205 Integrated Operating Manual

Integrated semi automatic arc welding machine
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REDI-MIG 205 Integrated
Integrated Semi Automatic Arc Welding Machine
Part No.
Description
KA1431-1
REDI-MIG 205i
KA1431-11
REDI-MIG 205i
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.
OPERATING MANUAL
for codes 70036 and below
Input Volts
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.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS
A.B.N. 36 000 040 308
IMA 597B
February 2004
EMC Compliant

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Summary of Contents for Lincoln Electric REDI-MIG 205 Integrated

  • 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: Arc Welding Safety Precautions

    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

    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: Instructions For Electromagnetic Compatibility

    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 record your equipment identification information below for future reference. This information can be found on your machine nameplate.
  • Page 7 INDEX Page INSTALLATION Location Connection to Mains Supply Shielding Gas Supply (for the Gas Metal Arc Welding Process) Gun and Cable Installation OPERATING INSTRUCTIONS Duty Cycle Control Panel SETTING UP FOR WELDING WELDING Changing Electrode Size and Type Adjusting Spool Tension LEARNING TO WELD The Arc-Welding Circuit The Self-Shielded (Gasless) FCAW Welding Arc...

  • Page 8: Product Description

    PRODUCT DESCRIPTION The REDI-MIG 205 Integrated is a fully integrated semi-automatic Constant Voltage DC arc welding machine. The REDI-MIG 205 Integrated 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: Shielding Gas Supply (For The Gas Metal Arc Welding Process)

    Refer “Safety in Welding and Cutting” - ANSI Standard Z49-1 and WTIA The REDI-MIG 205 Integrated is shipped from the factory Technical Note 7 available from the Welding Technology connected electrode (+)ve. This is the normal polarity for Institute of Australia.
  • Page 10 OPERATING INSTRUCTIONS 2.2 Control Panel WARNING Power Switch • Do not touch electrically live parts The mains power switch is incorporated in the “coarse” or electrode with skin or wet output voltage control rotary switch. In the “OFF” positions clothing. the input mains power is switched off.

  • Page 11: Setting Up For Welding

    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 12 REDI-MIG 205 IMA 597B...

  • Page 13: Learning To Weld

    Note: Ensure that the correct gun liner and contact tip are the coarse and fine rotary voltage switches. (Refer to used for different wire sizes and processes. Change gun REDI-MIG 205 Integrated Welding Guide suggested liner as necessary. See Section 6.5 Liner Removal, settings).

  • Page 14: Common Metals

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

    5.7 Welding Techniques For The Self- Figure 4 Shielded (Gasless) FCAW Process Four simple manipulations are of prime importance when Contact Tip 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: Welding Techniques For The Gmaw (Mig) Process

    They are as follows: 1. The Correct Welding Position Figure 8 illustrates the correct welding position for right handed people. (For left handed people, it is the For the REDI-MIG 205 Integrated, use the following: opposite.) Mild Steel Plate 3.0mm...

  • Page 17: Joint Types And Positions

    Refer to Figure 4. Unless a butt weld penetrates close to 100% of the metal For the REDI-MIG 205 Integrated, use the following: thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure 12, the Mild Steel Sheet (1.6 mm)

  • Page 18: Fillet Welds

    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: Maintenance

    Welding Thermal Overload Protection If a wire size other than that stamped on the roll is to be used, the drive roll must be changed. The REDI-MIG 205 Integrated has built-in protective thermostats that respond to excessive temperature. They Avoiding Wire Feeding Problems...

  • Page 20: Ground Test Procedure

    6.5 Liner Removal, Installation and Trimming Insert a new untrimmed liner into the connector end of the cable. Fully seat the liner bushing into the Euro connector. Tighten Instructions for REDI-MIG 240 MIG Gun the liner nut cap on the brass cable connector. The gas Note: The variation in cable lengths prevents the diffuser, at this time, should not be installed onto the end of interchangeability of liners between guns.

  • Page 21: Troubleshooting

    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 What To Do Problem...
  • Page 22 TROUBLESHOOTING What To Do Problem Possible Cause Measure the voltage between the motor No wire feed, although arc Defective wire feed motor or wire drive leads (54) and (53) when the Gas voltage is present. control PC board. Purge/Wire Inch toggle switch is pressed downwards.
  • Page 23 Operating Manual ........

  • Page 24: General Assembly

    AP-205C Operative: Feb 2004 General Assembly Supersedes: Apr 2001 AG 1417-1 and 5 Page 24 REDI-MIG 205 IMA 597B...
  • Page 25 AP-205C.1 Operative: Feb 2004 Supersedes: Apr 2001 Use only the parts marked “X” in the column under the # Indicates a change this printing. heading number called for in the model index page. * Items not illustrated. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION PART NO.
  • Page 26 AP-205C2 Operative: Feb 2004 General Assembly Supersedes: Apr 2001 AG 1417-1 and 5 Page 26 REDI-MIG 205 IMA 597B...
  • Page 27 AP-205C4 Operative: Feb 2004 Supersedes: Apr 2001 Use only the parts marked “X” in the column under the # Indicates a change this printing. heading number called for in the model index page. * Items not illustrated. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION PART NO.

  • Page 28: Control Panel Assembly

    AP-205D Control Panel Assembly Operative: Feb 2004 Supersedes: Apr 2001 AL 2683-1 D et ail "A" DETA IL A 23 24 20 21 17 18 Page 28 REDI-MIG 205 IMA 597B...
  • Page 29 T13562 DPDT Toggle Switch (Sprung) AS4706 Wire Drive Mounting Bracket AM3390-3 Wire Drive Motor AM3366-1 Thread Rolling Screw S9225-45 Nameplate REDI-MIG 205 Integrated AL2691-1 Euro Gun Adapter AM3025-2 Plastic Insulator AM3025A2 Black Knob 1.5” Dia T10491 Pilot Light, 240v, Amber...

  • Page 30: Cover Panels

    AP- 58E Cover Panels Operative: May 2001 Supersedes: N.A. N.A. Ref: AM3608 (A13-10-99) AP- 58E1 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-205W Wiring Diagram Operative: 7.6.00 Supersedes: 13.10.99 IMA 597B REDI-MIG 205 Page 31...
  • Page 32 AP-49D REDI-MIG 240 Operative: 4.7.03 Supersedes: MIG Gun Page 32 REDI-MIG 205 IMA 597B...
  • Page 33 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 34 NOTES Page 34 REDI-MIG 205 IMA 597B...
  • Page 35 NOTES IMA 597B REDI-MIG 205 Page 35...
  • Page 36 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...

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Redi-mig 205iKa1431-1Ka1431-11

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