Redi Mig 455

OPERATING MANUAL

REDI-MIG 455 Remote

Semi Automatic Arc Welding Machine

This manual applies to

Part No.

KA1443-2

Code

F948

Description

REDI-MIG 455

Remote

Volts

415

IMA 603

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.

Most importantly, think before you act and be careful.

ACN 000 040 308

IMA 603

THE LINCOLN ELECTRIC COMPANY

(AUSTRALIA) PTY. LTD.

A.B.N. 36 000 040 308

SYDNEY. AUSTRALIA

A Subsidiary of

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

REDI-MIG 455 Remote Page

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

ELECTRIC SHOCK can kill ARC RAYS can burn

1.

a.

The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing.

Wear dry, hole-free gloves to insulate hands.

b.

In semi-automatic and automatic wire welding, the electrode, electrode reel, welding head and nozzle or semi-automatic welding gun are also electrically “hot”.

c.

Insulate yourself from work and ground using dry insulation. When welding in damp locations, on metal framework such as floors, gratings or scaffolds, and when in positions such as sitting or Lying, make certain the insulation is large enough to cover your full area of physical contact with work and ground.

d.

Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

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. Replace damaged insulation.

g.

Never dip the electrode holder in water for cooling.

h.

Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

i.

When working above floor level, protect yourself from a fall should you get a shock.

j.

Also see items 4c and 6.

FUMES AND GASES can be dangerous

2.

a.

Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding on galvanised, lead or cadmium plated steel and other metals which produce toxic fumes, even greater care must be taken.

b.

Do not weld in locations near chlorinated hydrocarbon vapours coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapours to form phosgene, a highly toxic gas, and other irritating products.

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 breathing air is safe.

d.

Read and understand the manufacturer’ s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices.

e.

Also see Item 7b.

3.

a.

Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.

Headshield and filter lens should conform to AS

1674.2-1990 standards.

b.

Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays.

c.

Protect other nearby personnel with suitable non flammable screening and/or warn them not to watch the arc or expose themselves to the arc rays or to hot spatter or metal.

WELDING SPARKS can cause fire or explosion

4.

a.

Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Have a fire extinguisher readily available.

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

Technical Note 7 “Health and Safety in Welding” 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.

Accidental contact can cause overheating and create a fire hazard.

d.

Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapours from substances inside. These can cause an explosion even though the vessel has been “cleaned”.

For information purchase AS 1674-1990.

e.

Vent hollow castings or containers before heating, cutting or welding. They may explode.

f.

Sparks and spatter are thrown from the welding arc.

Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

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 the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

h.

Also see Item 7c.

Page 2 REDI-MIG 455 Remote IMA 603

CYLINDER may explode if damaged

5.

a.

Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators, designed for the gas and pressure used. All hoses, fittings, etc. should be 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.

Cylinders should be located :

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks or flame.

d.

Never allow the electrode, electrode holder, or any other electrically “hot” parts to touch a cylinder.

e.

Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

f.

Valve protection caps should always be in place and hand-tight except when the cylinder is in use or connected for use.

g.

Read and follow the instructions on compressed gas cylinders and associated equipment, and AS 2030

Parts 1 & 2.

FOR ELECTRICALLY powered equipment

7.

FOR ENGINE powered equipment

a.

Turn the engine off before troubleshooting 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.

Do not add fuel near an open flame, welding arc or when the engine is running.

Stop the engine and allow it to cool before refuelling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

d. Keep all equipment, safety guards, covers and devices in position and in good repair.

Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

f.

Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

g. To prevent accidentally starting petrol engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

6.

a.

Turn off input power using the disconnect switch at the fuse box before working on the equipment.

b.

Install equipment in accordance with the SAA Wiring

Rules, all local codes and the manufacturer’s recommendations. c.

Ground the equipment in accordance with the SAA

Wiring Rules and the manufacturer’s recommendations.

h. To avoid scalding do not remove the radiator pressure cap when the engine is hot.

HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE

For more detailed information it is strongly recommended that you purchase a copy of “Safety in Welding and Cutting - ANSI Standard Z

49.1” and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the Welding Technology Institute of

Australia, P.O. Box 6165, Silverwater NSW 2128. For copies of various Australian Standards contact your local S.A.A. office.

HOW TO ORDER REPLACEMENT PARTS

To ensure that you receive the correct replacement part the following procedure should be followed:

1. Quote Serial Number and Code Number.

2. Quote the Description, Item Number and Parts List Number of the desired part. When ordering parts for items carrying brand names of other companies, such as fan motors, drive shafts, etc., be sure to include the other company’s name and part number and other relevant information.

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” listing these shops geographically is available on request.)

Note: “Hardware” in the Lincoln Parts Lists are not Lincoln stock items but can be obtained via the Field Service Shop network.

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.

BUY ONLY GENUINE REPAIR PARTS

IMA 603 REDI-MIG 455 Remote Page 3

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WELDING, EMF & PACEMAKERS

All welders should follow safe practices that minimise their exposure to electric and magnetic fields (EMF).

Welders with pacemakers

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. (Hopefully in keeping with a doctor’s advice).

There is no question that the fields in arc welding can interfere with a pacemakers function. Generally the interference does not permanently damage the pacemaker. Once the wearer leaves the arc welding environment or stops welding, the pacemaker returns to normal functioning. The welding arc has little or no effect on the operation of some pacemakers, especially designs that are bipolar or designed to filter out such interference.

The following procedures will not eliminate exposure to EMF or 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.

For a welder or anyone working around electrical equipment the selection of a pacemaker is very important. Get a doctor’s advice about which pacemaker is the least sensitive to interference from welding while still being medically suitable.

Some researchers have reported that exposure to EMF may cause leukemia or other illnesses. These claims originally arose in relation to high voltage electric power lines and are very much in dispute in the medical and scientific arena, however the best advice is to minimise your exposure to EMF to protect your health should doctors eventually decide there is a risk.

•

•

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•

There are four fundamental facts about EMF:

With direct current (DC), the field strength is relatively constant and does not change.

With alternating current (AC), the field strength constantly changes.

The greater the current flow, i.e. the higher the amps, the stronger the field created by the current

The closer the conductor or electrical device is to the body, the greater the exposure to the field.

Minimising exposure

All welders should use the following procedures to minimise EMF exposure.

Route electrode or gun and work cables together. Secure them with tape if possible.

Never coil the electrode lead around your body.

Do not place your body between the electrode and work cables. If your electrode cable is on your right side the work cable should also be on your right side.

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 poor work connection.

Do not work next to the welding power source.

•

•

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•

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In addition to the normal safety precautions, the following additional procedures should be adopted by welders with pacemakers.

Use gas welding when the application is suitable.

Use the lowest current setting appropriate for the application. Do not exceed 400 amps. Low current

(75-200 amps) direct current (DC) welding should be used if arc welding is necessary. Do not TIG weld with high frequency.

Do not use repeated, short welds. Wait about ten seconds between stopping one weld and starting the next. When having difficulty starting an electrode, do not re-strike the rod repeatedly.

If you feel light headed, dizzy or faint, immediately stop welding. Lay the electrode holder down so that it does not contact the work and move away from any welding being performed. Arrange your work in advance so that, if you become dizzy and drop the electrode holder, the electrode holder will not fall on your body or strike the work.

Do not work on a ladder or other elevated position or in a cramped, confined place.

Do not work alone. Work only in the presence of an individual who understands these precautions and the possible effect welding may have on your pacemaker.

Do not work near spot welding equipment.

If you have a pacemaker and wish to continue arc welding, 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 mentioned before, the design of the pacemaker significantly affects the degree to which it is subject to interference from a welding circuit. Do not rely on the fact that you know another welder with a pacemaker who has welded for years without experiencing a problem.

That welder and his or her pacemaker may be quite different from you and your pacemaker.


INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY

WARNING

This welding machine must be used by trained operators only. Read this manual carefully before attempting to use the welding machine.

Conformance

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Products displaying the C-Tick mark are in conformity with

Australian/New Zealand requirements for Electromagnetic

Compatibility (EMC). They are: manufactured in conformity with Australian/New Zealand

Standard (Emission):- AS/NZS 3652 ‘Electromagnetic

Compatibility - Arc Welding Equipment’ (Identical to and reproduced from British Standard EN 50199) for using with other Lincoln Electric/LiquidArc equipment.

designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromanetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may effect many kinds of electrical equipment: other nearby welding equipment, radio and TV transmitters and receivers, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The purchaser/user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the 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 electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety 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. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

b.

c.

d.

Before installing welding equipment the purchaser/user shall make an assessment of potential problems in the surrounding area.

The following shall be taken into account: a.

Other supply cables, control cables, signalling and telephone cables above, below and adjacent to the welding equipment;

Radio and television transmitters and receivers;

Computer and other control equipment;

Safety critical safety equipment, eg. guarding of industrial equipment; e.

f.

The health of people around, eg. the use of pacemakers and hearing aids;;

Equipment used for calibration or measurement;

* g.

h.

The immunity of other equipment in the environment. The purchaser/user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

The time of the day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.If interference occurs, it may be necessary to take additional precautions such as filtering the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when 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’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, 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 increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference.

Screening of the entire welding installation may be considered for special applications.*

Portions of the preceding text are contained in AS/NZS3652:

‘Electromagnetic Compatibility - Arc Welding Equipment’.


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. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _______________________________________________

Code & Serial Number ________________________________________________

Date of Purchase ____________________________________________________

Read this Operator’s Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the Safety Instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.


INDEX

Section 1

1.1

1.2

1.3

1.4

1.5

Section 2

2.1

2.2

Section 3

Section 4

4.1

4.2

Section 5

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

5.13

5.14

5.15

5.16

5.17

Section 6 -

6.1

6.2

6.3

6.4

6.5

Section 7

Section 8

Section 9

INSTALLATION

Location

Connection to Mains Supply

Shielding Gas Supply (for the Gas Metal Arc Welding Process)

Gun and Cable Installation

Output Polarity Connection

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

The GMAW (MIG) Welding Arc

Process Selection

Common Metals

Machine Set Up for the Self-Shielded (Gasless) FCAW Process

Welding Techniques for the Self-Shielded (Gasless) FCAW Process

Machine Set Up for the GMAW (MIG) and Gas-Shielded FCAW Processes

Welding Techniques for the GMAW (MIG) Process

Joint Types and Positions

Butt Welds

Penetration

Fillet Welds

Welding in the Vertical Position

Vertical-Up and Overhead Welding

Vertical-Down Welding

Troubleshooting Welds

MAINTENANCE

Routine Maintenance

Gun and Cable Maintenance

Gun Tips and Nozzles

Input Lead

Liner Removal, Installation and Trimming Instructions for REDI-MIG 4 Torch

ACCESSORIES

GROUND TEST PROCEDURE

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

IMA 603 REDI-MIG 455 Remote

23

28

29

33

19

19

19

19

19

20

17

17

18

18

18

14

15

16

16

17

18

18

13

13

14

14

14

14

20

20

21

11

13

13

13

Page

8

8

8

9

9

9

10

10

10

34

36

Page 7

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.

Standard features include output volt and amp meter, a spot timer, gas purge facilities, wire inch, burnback control, a dual position 2 or 4 step trigger interlock, a REDI-MIG 4 MIG gun, a Harris 801 regulator/flowmeter and gas hose, a 5m ground cable assembly, a 5m long input lead and a twin cylinder undercarriage on which gas cylinders can be mounted.

Specifications

Model

Part No.

Maximum Open Circuit Voltage

Output Current Range

Duty Cycle

Rated Output

Rated Input AS1966

Wire Speed Range

Weight (complete with u/c)

35%

455A/36.5V


KA1443-2

47V

30 to 455A

415V 3ph 50Hz 19 amps

1-20 m/min

148 kg

60%

350A/31.5V

H x W x L (mm) Over handle cylinder tray & wheels

Operating Temperature

Dimensions do not include Wire Feeder

775 x 670 x 1050 mm*

-20˚C to 40˚C

*

WARNING

HIGH

VOLTAGE can kill

Section 1 - INSTALLATION

• Turn the input power o f f a t t h e disconnect switch before installing or servicing this machine.

• D o n o t t o u c h e l e c t r i c a l l y

“ h o t ” p a r t s s u c h a s o u t p u t terminals or internal wiring.

• Connect earthing screw ( ) t o a g o o d e a r t h g r o u n d .

• D o n o t o p e r a t e w i t h c o v e r s removed.

• Turn power switch “off” before c o n n e c t i n g o r d i s c o n n e c t i n g c a b l e s o r o t h e r e q u i p m e n t .

Only qualified personnel should install or service this equipment.

1.2 Connection to Mains Supply

Before connecting the machine to the mains supply check that the voltage and current capacity correspond to the machine voltage and rated input current. Use a fuse or C/B per AS3000 or local wiring rules.

The machine is supplied with an input lead fitted.

Have a qualified electrician fit a suitable input plug.

CAUTION

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 plugged into the mains outlet.

Machine Installation

1.1 Location

Place the welder where clean cooling air can freely circulate in through the front louvers and out through the rear louvers. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance thermostat trips.

1.3 Shielding Gas Supply (For the Gas Metal

Arc Welding Process)

Refer “Safety in welding and cutting” - ANSI Standard Z49-

1 and WTIA Technical Note 7, available from the Welding

Technology Institute of Australia.

Obtain cylinder of appropriate type shielding gas for the process being used.

CYLINDER may explode if damaged


1.

2.

3.

Set gas cylinder on rear platform of the machine. Hook chain in place to secure cylinder to rear of welder.

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 threads with a clean cloth.

DO NOT ATTACH THE REGULATOR/FLOWMETER IF

OIL, GREASE OR CYLINDER VALVE DAMAGE IS

PRESENT. OIL OR GREASE IN THE PRESENCE OF

HIGH PRESSURE OXYGEN IS EXPLOSIVE! Inform your gas supplier of this condition.

Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

WARNING

Be sure to keep your face away from the valve outlet when

“cracking” the valve.

4.

Inspect the regulator/flowmeter for damaged threads and seals, dirt and dust. Remove dust and dirt with a clean cloth.

WARNING

Gas under pressure is explosive. Always keep gas cylinders in an upright position and always keep chained 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

Institute of Australia.

5.

6.

7.

DO NOT USE THE REGULATOR/FLOWMETER IF

DAMAGE IS PRESENT! Have an authorised repair station repair any damage.

Attach the regulator/flowmeter to the cylinder valve and tighten the union nut(s) securely with a spanner.

Attach the machines inlet gas hose to the outlet fitting of the regulator/flowmeter, and tighten the union nut securely with a spanner.

Before opening the cylinder valve, turn the regulator adjusting knob counter-clockwise until the adjusting spring pressure is released.

WARNING

Never stand directly in front of or behind the regulator/flowmeter when opening the cylinder valve.

Always stand to one side.

8.

9.

Open the cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

The regulator/flowmeter is adjustable. Set it for the flow rate recommended for the procedure and process being used before starting to weld.

1.4 Gun and Cable Installation

WARNING

Turn the welder power switch off before installing gun and cable.

The REDI-MIG 4 MIG gun and cable provided with the machine has a factory fitted 0.9-1.2mm liner and a 1.2mm

contact tip.

1. Lay the cable out straight.

2. Make sure all pins on the gun cable connector are aligned with the proper mating sockets on the front panel gun connector and then join the connectors and tighten the hand nut on the gun cable connector.

Note: If a gun and cable other than the supplied gun is to be used, it must conform to standard European-style connector specifications. See diagram under.

The gun trigger switch must be capable of switching 10 milliamps at 60 volts DC—resistive.

CAUTION

The gun trigger switch connected to the gun trigger control cable must be a normally open, momentary switch.

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 electrical circuit other than the machine trigger circuit.

1.5 Output Polarity Connection

WARNING

Turn the welder power switch off before changing polarity.

The REDI-MIG 4D is connected to the REDI-MIG 455

Remote power source via a control/ electrode/gas cable assembly. The electrode cable is connected to the required female Twist-Mate terminal on the front of the REDI-MIG

455 Remote power source.

The control cable connects to the plug on the front panel between the positive and negative output connections of the REDI-MIG 455 Remote power source.

The gun polarity can be changed by placing the electrode cable to the required output connection on the front of the

REDI-MIG 455 Remote Power Source eg. for electrode (-

)ve, connect the electrode cable to the (-)ve output connection.

Connect the work lead to the other output connection.

(See connection diagrams Page 11).

Each output connection is a Twist-Mate terminal. To connect the output terminals, insert the correct mating

Twist-Mate plug and twist clockwise to secure. Twist anticlockwise and pull gently to release the Twist-Mate plug.


WARNING

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

ELECTRIC

SHOCK can kill

FUMES AND

GASES can be dangerous

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

• Keep flammable material away.

• Do not weld upon containers which have held combustibles.

WELDING SPARKS can cause fire or explosion

• Wear eye, ear and body protection.

ARC RAYS can burn

Section 2 - OPERATING INSTRUCTIONS

IMPORTANT SAFETY NOTE: In 2T mode {refer 2.2 (i)}, 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 triggered on in 4T mode.

2.1 Duty Cycle

The machine is rated at the following duty cycles:

Duty Cycle (1)

35%

Amps

455

Volts

36.5

60% 350 31.5

(1) Based on 10 min. time period (i.e., for 60% duty cycle, it is

6 minutes actual welding and 4 minutes with no welding output, but with the input power remaining on keeping the cooling fan operative.)

2.2 Control Panel

a) b) c) d) e)

Power Switch

The mains power switch is a two position toggle switch and is marked “POWER”. When the toggle switch is pressed downwards to the “O” position the input mains power is switched off.

Pilot Light

This light illuminates when the input mains power is switched on.

Volts Control

The output voltage is controlled by two rotary switches.

One rotary switch provides three “course” voltage settings.

The other rotary switch provides the user with a selection of ten fine voltage settings. The selection between these two rotary switches allows the user to select any one of thirty welding voltages.

The Coarse Voltage rotary switch is marked with the three coarse ranges A, B and C.

A) is the low range which supplies voltage from 16 to

18.5V.

B) is the medium range which supplies voltage from 18.5

to 24V.

C) is the high range which supplies voltage from 24 to

36.5V.

The fine voltage rotary switch is marked with the ten welding voltages a, b, c, d, e, f, g, h, i and j.

Wire Feed Speed Control *

Use this control to adjust the speed at which the electrode wire feeds when welding. This is in effect a current control as the power source will deliver the current necessary to melt the wire. The higher the speed, the more current will be required. Wire feed speed range is approximately 1 to

20 meters/min (40 to 790 inches/min.).

Operation of the gun trigger switches the wire feed motor on and off, depending upon the trigger mode setting. The wire feed motor is dynamically braked to minimise wire overrun after welding has ceased.

Welding voltage is available immediately the gun trigger is operated. When welding is stopped there is a delay to allow the electrode to burn back slightly and prevent sticking in the crater. [See Burnback Control 2.2 f)]

Inductance Settings

The inductance can be changed by changing the position of the negative output connection. The negative output connection closest to the side panel work is the High

Inductance Negative Output Connection.

The High Inductance Negative Output Connection is symbolised by “ “.

The High Inductance Negative Output Connection is more suitable when a soft arc is preferred.

The negative output connection furthest from the side panel work is the Low Inductance Negative Output

Connection.

The Low Inductance Negative Output Connection is symbolised by “ “.

The Low Inductance Negative Output Connection is more suitable when a crisp arc is preferred.


f) g) h)

Burnback Control *

This control is located in the wire feed bay. The burnback control adjusts the time period from when the drive motor stops until the power source and gas solenoid are switched off. [Approximately 0.1 seconds (when fully counterclockwise) to approximately 1.1 seconds (when fully clockwise)].

The purpose of the burnback control is to prevent the electrode wire sticking in the weld crater at the finish of the weld.

Spot Welding *

In spot welding mode, welding takes place for a pre-set time and then stops automatically. Welding time is adjustable between 0.5 sec. and 4 sec. by operation of the spot weld control on the front panel. There is a positive click in the extreme anti-clockwise position to indicate that the spot weld feature is “off”.

Gas Purge/Wire Inch *

Use the gas purge momentry toggle switch to operate the gas solenoid to purge air from the hose after connecting a new gas cylinder. Gas purge will only operate while the toggle switch is held upwards.

* i) j)

Use this same toggle switch to operate the wire feed motor and “cold” inch the wire, by pushing the toggle switch downwards.

2 Step/4 Step Trigger Operation *

A two position toggle switch on the front panel provides two modes of operation of the gun trigger. In 2 Step mode, the gun trigger is pressed to start welding and released to stop.

In 4 Step mode, pressing the gun trigger only operates the gas solenoid, allowing shielding gas to flow. Releasing the trigger activates the contactor which starts the wire feed motor and connects welding current to the wire so that welding may commence. To stop welding, the trigger must again be operated; pressing it stops the wire feed, activates the burn back time delay and opens the contactor after the pre-set burn back time. Releasing the trigger stops the gas flow.

To recommence welding, the above cycle must be repeated.

Over temperature light

Indicates that the thermostats have operated to protect unit from over temperature.

Mounted on REDI-MIG 4D wire feeder (Burnback is mounted in the wire bay area).

The following items are required:

1)

2)

3)

Section 3 - SETTING UP FOR WELDING

A reel of wire of suitable size and type .

A suitable gun and cable assembly with a “Euro” connector and the correct tip and, if necessary gas nozzle for the consumable being used. (A REDI-MIG 4 gun is supplied).

Correct drive rolls for the wire size and type to be used. The wire feeder is supplied with a 0.9/1.2mm solid wire feed roll as standard; drive rolls for other types and sizes are available as spare parts. (see table on page 13).

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, between the drive rolls, and into the “Euro” connector guide until it protrudes about 20mm out of the front of the “Euro” connector.

Close the drive rolls by lowering the cam latch ensuring the rolls firmly hold the wire. Ensure the wire is correctly aligned between all four rolls and that the drive roll gear teeth mesh correctly before lowering the cam latch. Poor alignment of wire or drive roll gear teeth may cause wire slipping.

4)

5)

A work return cable and clamp.(supplied)

Normal welding accessories including helmet or hand shield with suitable lens, gloves etc.

Refit the gun and cable assembly onto the “Euro” connector by slipping the end of wire into the cable wire hole. Tighten the “Euro” connector lock ring. (Refer Section 1.4 - Gun and Cable

Installation for further instructions).

6) If a gas shielded process is to be used, a cylinder of appropriate gas is required. (Regulator/flowmeter and hose are supplied.) If gas shielding is required, connect the gas per Section 1.3 of this manual.

Connect the control cable (a 4 pin male plug attached to the wire feeder) to the 4 pin female plug on the front of the REDI-MIG 455

Remote power source, between the positive and negative output connections.

Remember that gas cylinders may explode if damaged, so ensure that all gas cylinders are securely mounted.

Ensure that the correct type and size wire feed rolls are fitted. In replacing wire feed rolls, ensure that the key and keyway are correctly positioned and tighten the knurled locking screw securely.

It is best to remove the gun before loading a new spool of wire.

Activate the power source, set the wire feed speed to 4 on the dial and press the Gas Purge/Wire Inch toggle switch downwards. The wire feed roll should turn, feeding the wire further up the gun and cable assembly. (Adjust the tension on the drive roll cam latch so that the wire feeds smoothly. Do not overtighten).

Ensure there are no kinks or sharp bends in the gun cable and hold the Gas Purge/Wire Inch toggle switch downwards until the wire emerges from the gun. It is good practice to remove the tip when first feeding a new coil of wire, then refitting the tip over the wire and tightening.

Fit a spool of appropriate wire onto the 50mm spool hub so that, as wire is fed, the spool turns clockwise. Carefully release the end of the wire from the spool ensuring that the released end is held to stop the wire from unravelling. Cut off the end kink to give a smooth straight end of wire.

Cut off the end of the wire leaving 10mm to 15mm stick-out from the tip.

Select required polarity. See Section 1.5 - Output Polarity

Connection and diagrams below.

Gas Shielded Wires Gasless Wires

DC+

SETUP

DC-

SETUP

IMA 603

Negative Output Stud

Work Lead

Positive Output Stud

To Wire Feeder


Negative Output Stud

To Wire Feeder

Positive Output Stud

Work Lead

Page 11


WARNING

Section 4 - WELDING

All required equipment for aluminium welding is supplied in the optional 1.2mm Aluminium Feeding Kit (KA1440-3).

When the gun trigger is pressed (2 mode) or pressed and released the first time (4 mode), 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.

When changing to cored wire welding, a new drive roll should be used. All required equipment for cored wire welding is supplied in the optional 1.2mm Flux Cored

Feeding Kit (KA1441-3).

Also check electrode polarity, as different processes may require different polarities.

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,

Installation and Trimming Instructions for REDI-MIG 4

Torch.

Put into 2 Step trigger mode.

Select the output voltage required to suit the job by setting the coarse and fine rotary voltage switches. (Refer to

REDI-MIG 455 Welding Guide suggested settings).

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 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.

If it is necessary to adjust the weld voltage, stop welding before changing either or both of the rotary voltage switches.

Adjust the wire feed speed as necessary to suit the job. At the completion of the weld, release the gun trigger and pull the gun away from the work to stop the arc.

4 Step trigger mode should only be used for long welds by experienced operators.

Available Drive Rolls

Part No.

AS4449-9

AS4449-11

AS4449-8

AS4449-2

AS4449-5

AS4449-12

AS4449-6

AS4449-3

AS4449-13

AS4449-4

Size (mm)

0.6 - 0.8

0.8 - 0.9

0.9 - 1.2

1.0 - 1.2

0.8 - 1.0

0.9 - 1.2

1.2-1.6

0.8 - 1.0

0.9 - 1.2

1.2 - 1.6

* Standard on REDI-MIG 455 Remote.

Use with

Solid Wire

Solid Wire

Solid Wire *

Solid Wire

Aluminium Wire

Aluminium Wire

Aluminium Wire

Cored Wire

Cored Wire

Cored Wire

4.1 Changing Electrode Size and Type

When 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 and keyway and firmly secured by knurled screw.

When changing to aluminium welding a new drive roll, cable liner and contact tip should be used.

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 adjusting the large nut inside the hub with a tube spanner.

Section 5 - LEARNING TO WELD

No 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.

FUMES AND GASES can be dangerous

5.1 The Arc-Welding Circuit

The 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.

This machine’s welding circuit has a voltage output of 47 volts DC maximum. This voltage is quite low and is only present when the gun trigger is depressed.

To 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.

•

•

•

•

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.

Follow all safety precautions found in this operating manual.

The 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.

Arc 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.


5.2 The Self-Shielded (Gasless)

FCAW Welding Arc (DC-)

Figure 1 illustrates the action taking place in the self shielded gasless FCAW welding arc. It closely resembles what is actually seen while welding.

Figure 1

Cored Wire

Protective Slag

Weld Metal

Burning of core materials inside wire electrode results in shield of gas.

Arc Stream

The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about

3300°C, which is more than enough to melt metal.

The arc is very bright, as well as hot, and cannot be looked at with the naked eye without risking painful injury. The very dark lens, specifically designed for arc welding must be used with the hand or face shield whenever viewing the arc.

The arc melts the base metal and actually digs into it much as water through a nozzle on a garden hose digs into the earth. The molten metal forms a molten pool or crater and tends to flow away from the arc. As it moves away from the arc, it cools and solidifies.

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 which a steel sheath has been formed. It is simply a stick electrode turned inside out in a continuous wire form.

The cored wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool. The wire sheath provides additional filler metal for the joint to fill the groove or gap between the two pieces of base metal.

The core materials also melt or burn in the arc and perform 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 impurities and forms the protective slag on top of the weld during cooling.

After running a weld bead, the slag may be removed with a chipping hammer and wire brush. This improves appearance and allows for inspection of the finished weld.

Machine size and output characteristics limit the size and type of wire electrode which can be used.

5.3 The GMAW (MIG) Welding Arc (DC+)

Figure 2 illustrates the GMAW (MIG) welding arc. Solid wire does not contain fluxes or ingredients to form its own shielding and no slag forms to protect the molten weld metal. For this reason, a continuous even flow of shielding gas is needed to protect the molten weld metal from atmospheric contaminants such as oxygen and nitrogen.

Shielding gas is supplied through the gun and cable assembly, through the gas nozzle and into the welding zone.

Figure 2

Solid wire electrode

Page 14

Gas nozzle

Shielding gas

When comparing the GMAW and FCAW processes, you can see that the principal difference between the two lies in the type of shielding used. GMAW uses gas for shielding, thus we have Gas Metal Arc Welding. FCAW uses the melting or burning of the core ingredients for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding.

Gas Metal Arc Welding (MIG) is capable of welding a wide range of mild steels in all positions, however, more skill is required for out-of-position welding with the GMAW process.

5.4 Process Selection

By gaining knowledge of the differences between the two processes, you will be able to select the best process for the job you have at hand. In selecting a process, you should consider:

For GMAW (MIG) Process

1. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas supply?

2. Do I require clean, finished-looking welds?

If you have answered yes to all the above questions

GMAW may be the process for you. If you have answered no to any of the above questions, then you should consider using the FCAW process.

For FCAW (Innershield) Process

1. Do I want simplicity and portability?

2. Will welding be performed outdoors or under windy conditions?

3. Do I require good all position welding capability?

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 be easily welded without special precautions. Some steels, however, contain higher carbon levels or other alloys and are more difficult to weld. Basically, if a magnet sticks to the metal and you can easily cut the metal with a file, chances are good that the metal is mild steel and that you will be able to weld the material. In addition, aluminum can be welded using the an aluminum welding kit (KA1440-3). For further information on identifying various types of steels and other metals, and for proper procedures for welding them, we suggest you purchase a copy of “New Lessons in

Arc Welding”.

Regardless of the type of metal being welded, in order to get a quality weld, it is important that the metal is free of oil, paint, rust or other contaminants.

5.6 Machine Set up for the Self-Shielded

(Gasless) FCAW Process

1.

Ensure the machine has the correct drive roll and parts (all required parts for cored wire welding are supplied in the

Innershield (Gasless) Welding Kit KA1441-3). Best results using self-shielded flux cored wires are obtained when using a gun specially designed for these types of wires such as the KA1325 Innershield Gun.

2.

3.

4.

5.

See the Welding Procedure Guide on the inside of wire feed section door for information on setting the controls.

Set the “Voltage” and “Wire Speed” controls to the settings suggested on the Welding Procedure Guide for the welding wire and base metal thickness being used.

Check that the polarity is correct for the welding wire being used. See Section 1.5 for instructions on changing polarity.

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 “Arc

Welding Safety Precautions” at the beginning of this manual.

REDI-MIG 455 Remote IMA 603

5.7 Welding Techniques For The Self-

Shielded (Gasless) FCAW Process

Four simple manipulations are of prime importance when welding. With complete mastery of the four, welding will be easy. They are as follows:

1. The Correct Welding Position

Figure 3 illustrates the correct welding position for right handed people. (For left handed people, it is the opposite.)

Hold the gun (of the gun and cable assembly) in your right hand and hold the shield with your left hand. (Left handers simply do the opposite.)

When using the FCAW Process, weld from left to right

(if you are right handed). This enables you to clearly see what you are doing. (Left handers do the opposite.) Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure 3.

Figure 3

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, you may stick the contact tip or nozzle to the weld puddle and/or fuse the wire to the contact tip.

4. The Correct Welding Speed

The important thing to watch while welding is the puddle of molten metal right behind the arc. See Figure 5. Do not watch the arc itself. It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicates correct welding speed. The ridge should be approximately 10 mm behind the wire electrode.

Most beginners tend to weld too fast, resulting in a thin uneven, “wormy” looking bead. They are not watching the molten metal.

Figure 5

Solidifying ridge

Molten puddle

ARC RAYS can burn eyes and skin

When using an open arc process, it is necessary to use correct eye, head and body protection.

Protect yourself and others, read “ARC RAYS can burn” at the front of this manual.

2. The Correct Way To Strike An Arc

1. Be sure the work clamp makes good electrical contact to the work.

2. Position gun over joint. End of wire may be lightly touching the work.

3. Position face shield to protect face and eyes, close gun trigger, and begin welding. Hold the gun so that the contact tip to work distance is about 10 - 12 mm.

4. To stop welding, release the gun trigger and pull the gun away from the work after the arc goes out.

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 simply bending the wire back and forth until it breaks off.

6. When no more welding is to be done, turn off the machine.

3. The Correct Electrical Stickout (ESO)

The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire.

See Figure 4.

Once the arc has been established, maintaining the 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)

Helpful Hints

1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier.

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 slowly in order to get good penetration.

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 backstepping method illustrated in Figure 6.

Figure 6

First weld from A to B; then from C to A; then from D to C; then from E to D, and so on.

B A C D E

Back-Stepping

Practice

The best way of getting practice in the four skills that enable you to maintain:

1. Correct welding position

2. Correct way to strike an arc

3. Correct electrical stickout

4. Correct welding speed is to perform the following exercise.


Figure 7 Figure 8

For the REDI-MIG 455 Remote, use the following:

Mild Steel Plate

Electrode

Voltage Setting

Wire Feed Speed

3.0mm

1.2mm

Innershield 211 MP

Af

4

Refer to Figure 7.

1.

Learn to strike an arc by positioning the gun over the joint and touching the wire to the work.

2.

3.

Position face shield to protect face and eyes.

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.

5.

6.

After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound.

When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc start moving. Look at the molten puddle constantly, and look at the “ridge” where the metal solidifies.

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 look considerably better than the first weld. By constantly checking on your mistakes and your progress, welding will soon be a matter of routine.

5.8 Machine Set Up for the GMAW (MIG)

Process and Gas Shielded GCAW

Processes

1.

The REDI-MIG 455 Remote comes ready for welding using the MIG process.

2.

3.

4.

5.

6.

See the Procedure Welding Guide on the inside of wire feed section door for information on setting the controls.

Set the “Voltage” and “Wire Speed” controls to the settings suggested on the Procedure Welding Guide for the welding wire and base metal thickness being used. ’

Check that the polarity is correct for the welding wire being used. Set the polarity for DC(+) when welding with the

GMAW (MIG) process. See Section 1.5 for instructions for changing polarity.

Check that the gas nozzle and proper size liner and contact tip are being used and that the gas supply is turned on. Set for 7 to 10 L/min. under normal conditions, increase to as high as 17 L/min. under drafty (slightly windy) conditions.

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 “Arc

Welding Safety Precautions” at the beginning of this manual.

Page 16

Figure 9


5.9 Welding Techniques for the GMAW (MIG)

Process

Four simple manipulations are of prime importance when welding. With complete mastery of the four, welding will be easy. 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 opposite.)

When GMAW (MIG) welding on sheet metal, it is important to use the “forehand” push technique.

Hold the gun (of the gun and cable assembly) in your right hand and hold the shield with your left hand. (Left handers simply do the opposite.) Weld from right to left

(if you are right handed). This results in a colder weld and has less tendency for burn through.

ARC RAYS can burn eyes and skin

When using an open arc process, it Is necessary to use correct eye, head and body protection.

Protect yourself and others, read “ARC RAYS can burn” at the front of this manual.

2. The Correct Way To Strike An Arc

1. Be sure the work clamp makes good electrical contact to the work.

2. Position gun over joint. End of wire may be lightly touching the work.

3. Position face shield to protect face and eyes, close gun trigger, and begin welding. Hold the gun so that the contact tip to work distance is about 10 - 12 mm.

4. To stop welding, release the gun trigger and pull the gun away from the work after the arc goes out.

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 cutting off the end of the wire with wire cutters.

6. When no more welding is to be done, close the valve on the gas cylinder, momentarily operate the gun trigger to release gas pressure, then turn off the machine.

IMA 603

3. The Correct Electrical Stickout (ESO)

The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure 9.

Once the arc has been established, maintaining the correct ESO becomes extremely important. The ESO should be approximately 10 to 12 mm long.

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, you may stick the contact tip or nozzle to the weld puddle and/or fuse the wire to the contact tip.

4. The Correct Welding Speed

The important thing to watch while welding is the puddle of molten metal right behind the arc. See Figure 10. Do not watch the arc itself. It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicates correct welding speed. The ridge should be approximately 10 mm behind the wire electrode.

Figure 10

Most beginners tend to weld too fast, resulting in a thin, uneven, “wormy” looking bead. They are not watching the molten metal.

5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving. Look at the molten puddle constantly,

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 look considerably better than the first weld. By constantly checking on your mistakes and your progress, welding will soon be a matter of routine.

5.10 Joint Types and Positions

Five types of welding joints are: Butt Welds, Fillet Welds,

Lap Welds, Edge Welds and Corner Welds. See Figure 10.

Of these, the Butt Weld and Fillet Weld are the two most common welds.

Figure 10

Butt weld Lap weld

Helpful Hints

1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier.

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 slowly in order to get good penetration.

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 backstepping method illustrated in Figure 6.

Practice

The best way of getting practice in the four skills that enable you to maintain:

1. Correct welding position

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:

Mild Steel Sheet

Electrode

Voltage Setting

Wire Feed Speed

(1.6 mm)

0.9mm L54/L56 Ultra electrode

Argon/CO

2

Af

Blend

5

Refer to Figure 7.

1. Learn to strike an arc by positioning the gun over the joint and touching the wire to the work.

2. Position face shield to protect face and eyes.

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. Learn to distinguish it by its sound.

IMA 603 REDI-MIG 455 Remote

Edge weld Fillet weld Corner weld

5.11 Butt Welds

Place two plates side by side, leaving a space approximately one half the thickness of the metal between them in order to get deeper penetration.

Securely clamp or tack weld the plates at both ends, otherwise the heat will cause the plates to move apart. See

Figure 11.

Now weld the two plates together. Weld from left to right (if right handed and using self-shielded FCAW process). Point the wire electrode down in the crack between the two plates, keeping the gun slightly tilted in the direction of travel.

Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.

Figure 11

þ

⌧

5.12 Penetration

Unless a butt weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure 12, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.

In the example shown in Figure 13, the joint has been welded so that 100% penetration could be achieved. The weld, if properly made, is as strong as or stronger than the original metal.

Figure 12

Page 17

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. It should not be used on heavy material where large welds are required.

Figure 16

5.13 Fillet Welds

When welding fillet welds, it is very important to hold the wire electrode at a 45° angle between the two sides or the metal will not distribute itself evenly. The gun nozzle is generally formed at an angle to facilitate this. See Figure

14.

Figure 14

45°

WARNING

Use of this unit on thicker materials than recommended may result in poor welds. The welds may “look” good, but may just be “sitting” on top, of the plate. This is called

“Cold Lapping” and will result in weld failure.

5.17 Troubleshooting Welds

Good welds have excellent appearance.

5.14 Welding In The Vertical Position

Welding in the vertical position can be done either verticalup or vertical-down. Vertical-up is used whenever a larger, stronger weld is desired. Vertical-down is used primarily on sheet metal 4.0 mm and under for fast, low penetrating welds.

5.15 Vertical-up And Overhead Welding

The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip”. Therefore, a certain technique has to be followed.

When welding out-of-position, run stringer beads. Don’t whip, break the arc, move out of the puddle, or move too fast in any direction. Use Wire Feed Speed (WFS) in the low portion of the range. The general technique and proper gun angle are illustrated in Figure 15.

Generally, keep the electrode nearly perpendicular to the joint as illustrated. The maximum angle above perpendicular may be required if porosity becomes a problem.

Figure 15

To Eliminate Porosity (in order of importance):

1. Turn on gas supply, if used

2. Decrease voltage.

3. Increase stickout.

4. Increase WFS (wire feed speed).

5. Decrease torch angle.

6. Decrease travel speed.

Note: Always be sure the joint is free from moisture, oil, rust, paint or other contaminants.

To Eliminate a Ropy Convex Bead (in order of importance):

Proper gun angle for GMAW process welding in the vertical up position.

PROPER GUN ANGLE

FOR GMAW PROCESS

WELDING IN THE VERTICAL UP POSITION

Proper gun angle for FCAW process welding in the vertical up

FOR FCAW PROCESS

WELDING IN THE VERTICAL UP POSITION

5.16 Vertical-down Welding

Refer to Figure 16 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 4.0 mm and lighter material.

Use stringer beads and tip the gun in the direction of travel so the arc force helps hold the molten metal in the joint.

Move as fast as possible consistent with desired bead shape.

1. Increase voltage

2. Decrease stickout.

3. Decrease WFS (wire feed speed).



6. Check for correct gas, if used.


To Reduce Spatter (in order of importance):

1. Increase voltage.

2. Increase torch angle.





To Correct Poor Penetration (in order of importance):



3. Increase voltage.

4. Decrease speed.



WARNING

If Arc Blow Occurs (in order of importance):

Note: Try different ground connection locations before adjusting procedures.


2. Increase stickout.

3. Decrease voltage.

4. Decrease WFS (wire feed speed.


To Eliminate Stubbing* (in order of importance):

1. Increase voltage

2. Decrease WFS (wire feed speed)

3. Decrease stickout

4. Increase torch angle

* Stubbing occurs when the electrode drives through the molten puddle and hits the bottom plate tending to push the gun up.

Proper Gun Handling

Most feeding problems are caused by improper handling of the gun cable or electrodes.

1. Do not kink or pull the gun around sharp corners

2. Keep the gun cable as straight as practical when welding.

3. Do not allow dolly wheels or trucks to run over the cables.

4. Keep the cable clean.

5. Use only clean, rust-free electrode. Lincoln electrodes have proper surface lubrication.

6. Replace contact tip when it becomes worn or the end is fused or deformed.

Section 6 - MAINTENANCE

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out.

• Have an electrician install and service this equipment.

CAUTION

ELECTRIC

SHOCK can kill

6.1 Routine Maintenance

General

• Turn the input power off at the fuse box, or unplug input lead before working on equipment.

• Do not touch electrically hot parts.

In extremely dusty locations, dirt may clog the air passages and cause the welder to run hot. Blow dirt out of the welder with low-pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

The fan motor has sealed ball bearings which require no service.

Welding Thermal Overload Protection

The REDI-MIG 455 Remote has built-in protective thermostats that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating temperature because of a frequent overload, or high ambient temperature plus overload. The over temperature light on the control panel glows if thermostats open. The thermostats automatically reset when the temperature reaches a safe operating level. The fan will stay on when the machines welding and feeding are disabled during thermostatic overtemperature protection.

Excessive pressure at the start may cause dirt to form a plug.

6.3 Gun Tips and Nozzles

The gun tip should be replaced when worn. Replace with the correct size for the wire type and diameter. Too large a tip for the electrode wire will cause arcing within the gun cable and possible jamming of the wire within the cable .

Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

Drive Rolls and Guide Tubes

After every coil of wire, inspect the wire drive mechanism.

Clean it as necessary by blowing with low pressure compressed air. Do not use solvents for cleaning the idle roll because this may wash the lubricant out of the bearing.

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 used, the drive roll must be changed.

Avoiding Wire Feeding Problems

Wire feeding problems can be avoided by observing the following gun handling procedures:-

1. Do not kink or pull gun cable around sharp corners.

2. Keep the gun cable as straight as possible when welding or feeding electrode through cable.

3. Keep gun cable clean by following maintenance instructions.

6.2 Gun and Cable Maintenance

Cable Cleaning

Clean cable liner after using approximately 150kg of electrode. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using an air hose and approx. 350 kPa (50psi) pressure, gently blow out the cable liner from the gas diffuser end.

IMA 603

4. Use only clean, rust-free electrode. Lincoln Electric electrode has proper surface lubrication.

5. Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed.

6.4 Input Lead

If the supply cord is damaged, it must be replaced by a qualified electrician.

REDI-MIG 455 Remote Page 19

°

°

6.5 Liner Removal, Installation and Trimming

Instructions for REDI-MIG 4 Torch

Note: The variation in cable lengths prevents the interchangeability of liners between guns. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement.

1.

2.

3.

Remove the gas nozzle and nozzle insulator, (if used), to locate the set screw in the gas diffuser which is used to hold the old liner in place. Loosen the set screw with an

Allen key.

Remove the gas diffuser from the gun tube.

Lay the gun and cable out straight on a flat surface.

Loosen the liner nut cap located in the brass connector at the feeder end of the cable and pull the liner out of the cable.

4.

5.

6.

7.

8.

Insert a new untrimmed liner into the connector end of the cable.

Fully seat the liner bushing into the Euro connector.

Tighten the liner nut cap on the brass cable connector. The gas diffuser, at this time, should not be installed onto the end of the gun tube.

With the gas diffuser still removed from the gun tube, be sure the cable is straight, and then trim the liner to length.

Remove any burrs from the end of the liner.

Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser is correct for the liner being used.

Tighten the set screw in the side of the gas diffuser against the cable liner using an Allen key. Do not overtighten.

Section 7 - ACCESSORIES

° Drive Rolls for mild steel, stainless steel and aluminium for solid wires as well as for flux cored wires. See your nearest

Lincoln distributor for details.

1.2mm Flux Cored, Gas and Gasless Welding Kit, complete with 2 x 0.9, 1.2mm knurled drive rolls, 0.9-

1.2mm torch liner and packet of 10 x 1.2mm contact tips

(KA1441-3).

1.2mm Aluminium Welding Kit complete with 2 x 0.9mm,

1.2mm U-groove drive rolls, 0.9-1.2mm Teflon torch liner, packet of 10 X 1.2mm contact tips, Teflon inlet and outlet guides (KA1440-3).

° Innershield (Self Shielded or Gasless Wire) Welding Gun with Euro connect fitting for best results with gasless wires

(KA1325).

Section 8 - GROUND TEST PROCEDURE

WARNING

5) Unplug digital meter PCB plug.

This procedure is only suitable for applications using DC mega testers up to 500V.

6) Switch the fine control rotary switch to position ‘a’ & switch the coarse control rotary switch to position ‘A’.

ELECTRIC SHOCK

7) Primary test: Connect one lead of the mega tester to the frame of the machine and the other lead to each of the three (3) input conductors and to the main transformer primary leads L1A, L2A & L3A. Apply the test(s).

can kill

Note: This procedure is for ‘machines as built’ many modifications could have taken place over the life of a particular machine, so details of this procedure may need to be ‘adjusted’ to suit these modifications.

8)

9)

Welding circuit test: Connect one lead of the mega tester to the frame of the machine and the other lead to the positive output stud. Apply the test. (Min resistance 1M

Ω

).

For prompt service contact your local Lincoln Field Service Shop.

The insulation resistance values listed below are from Australian

Standard AS1966.1.

Welding circuit to primary test: Connect one lead of the mega tester to the positive output stud and the other lead to each of the three (3) input conductors and to the main transformer primary leads L1A, L2A & L3A. Apply the test.

(Min resistance 10M

Ω

).

1)

2)

Disconnect input cable from power outlet.

Disconnect all output cables (control & weld).

10) Transformer thermostat test: Connect one lead of the mega tester to the frame of the machine and the other lead to the positive output stud. Apply the test.(Min resistance

1M

Ω

).

3) Remove the roof panel.

11) Remove all jumper leads.

4) Jumper the three (3) AC terminals and the (+) & (-) terminals of the three phase bridge rectifier (A total of five

(5) places).

12) Refit the roof panel.

Procedure for Replacing PC Boards

Before replacing a PC board suspected of being defective, visually inspect the PC board in question for any visible damage to any of its components and conductors on the back of the board.

1.

If there is no visible damage to the PC board, install a new one and see if this remedies the problem. If the problem is remedied, reinstall the original PC board to see if the problem still exists. If the problem no longer exists with the old PC board: a. Check the PC board harness connector pins for corrosion, contamination, or looseness.

2.

3.

b. Check leads in the plug harness for loose or intermittent connection.

If PC board is visibly damaged, before possibly subjecting the new PC board to the same cause of failure, check for possible shorts, opens or grounds caused by: a. Damaged lead insulation.

b. Poor lead termination, such as a poor contact or a short to adjacent connection or surface.

c. Shorted or open motor leads, or other external leads.

d. Foreign matter or interference behind the PC board.

If PC board is visibly damaged, inspect for cause, then remedy before installing a replacement PC board.

Changing Settings for Motor Acceleration

If Motor Acceleration needs to be altered from factory setting, because of the welding procedure being used, locate the PCB in the REDI-MIG 4D Remote Wire Feeder.

Page 20

On the PCB there is a trimmer labelled ‘Rampa’, this trimmer controls the acceleration rate of the drive motor from stationary to the set wire feed speed. Maximum acceleration when fully counter-clockwise to minimum acceleration when fully clockwise.

This is particularly important when welding aluminium wire. The factory setting is fully clockwise.

REDI-MIG 455 Remote IMA 603

Section 9 - TROUBLESHOOTING

WARNING

ELECTRIC

SHOCK can kill

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box, or unplug input lead before working on equipment.

• Do not touch electrically hot parts.

Problem

Rough wire feeding or wire not feeding but drive rolls turning.

Variable or “hunting” arc.

Poor arc striking with sticking or “blast offs”, weld porosity, narrow and ropey looking bead, or electrode stubbing into plate while welding.

Tip seizes in diffuser.

Possible Cause

Gun cable kinked and/or twisted.

Wire jammed in gun and cable.

Incorrectly fitted drive roll.

Drive roll loose.

Gun cable dirty.

Worn drive roll.

Electrode rusty and/or dirty.

Worn nozzle or cable liner.

Partially flashed or melted contact tip.

Incorrect idle roll pressure.

Wrong size, worn and/or melted contact tip.

Worn work cable or poor work connection.

Loose electrode connections.

Wrong polarity.

Improper procedures or techniques.

Improper gas shielding.

Tip overheating due to prolonged or excessive high current and/or duty cycle welding.

What To Do

Inspect gun cable and replace if necessary.

Remove wire from gun and cable - feed in new wire. Note any obstructions in gun and cable.

Replace gun and cable if necessary.

See Wire Drive Roll Section in this manual for proper installation of drive roll.

Remove, clean, install and tighten.

Clean cable or replace liner.

Replace.

Replace.

Replace.

Replace contact tip.

Set idle roll pressure.

Replace tip - remove any spatter on end of tip.

Inspect - repair or replace as necessary.

Be sure electrode lead is tight, gun cable tight in wire feeder contact block, gun nozzle and gun tip tight. All work lead connections must be tight.

Check connection at output studs for polarity required by welding process.

See “Gas Metal Arc Welding Guide” (GS100).

Clean gas nozzle. Make certain that gas diffuser is not restricted. Make certain that gas cylinder is not empty or turned off. Make certain gas solenoid valve is operating and gas flow rate is correct.

Remove gun liner and check rubber seal for any sign of deterioration or damage. Be sure set screw in brass connector is in place and tightened against the liner bushing.

Do not exceed current and duty cycle rating of gun.

A light application of high temperature antiseize lubricant may be applied to tip threads.


Problem

No wire feed, although arc voltage is present.

No control of wire feed.

TROUBLESHOOTING

Possible Cause

Defective wire feed motor or wire drive control PC board.

What To Do

Measure the voltage between the motor leads (54) and (53) when the Gas

Purge/Wire Inch toggle switch is pressed downwards. If this voltage is over 10V

DC, replace the wire feed motor. If no voltage is registered, replace the wire drive PCB. (Refer PCB replacement procedure on page 19).

Defective wire drive control PC board.

Replace PCB. (Refer PCB replacement procedure on page 19).

No wire feed and no arc voltage. Pilot light indicates input power to machine.

Overtemperature protection circuit actuated due to overload or short.

(Overtemperature light should be illuminated).

Faulty gun trigger switch or damaged control cable connected to gun trigger.

Defective control PC board.

Allow machine to cool down and reduce on time and/or wire feed speed.

Repair.

Refer Procedure for Replacing PC

Boards, if no fault is detected in triggerthermostat circuit.

Replace defective contactor.

Defective contactor.

Poor welding characteristics and/or cannot obtain full rated output as per nameplate.

Improper settings for wire feed speed and volts.

Faulty switch either coarse control (on/off) or fine control.

Faulty pilot transformer.

Faulty main transformer.

Faulty rectifier.

Faulty choke.

One phase disconnected.

Set controls correctly.

Replace switch.

Replace.

Replace.

Replace

Replace.

Check fuses, check input connection.


Operative:

Supersedes:

AP-207

Sep 2001

NEW


KA1443-2 (415V)

Model Index

NUMBERS IN THE TABLE BELOW INDICATE WHICH

COLUMN TO USE IN EACH PARTS LIST FOR EACH

INDIVIDUAL CODE NUMBER.

DO NOT attempt to use this Parts List for machine if its code number is not listed. Contact the Service Department for any code numbers not listed. (Only those suffixes which require distinction from the basic codes are shown.)

PARTS

LIST

TITLES

PARTS LIST

NO.

CODE NO.

1572

1616

AP-207-C

1

1

AP-207-D AP-207-W

1

1

1

1

AP-56 AP-56-D AP-49-C

1

1

1

1

2

2

Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REDI-MIG 455

IMA 603

# Indicates a change this printing


General Assembly

Operative:

Supersedes:

AP-207C

Sep 2001

NEW


Operative:

Supersedes:

AP-207-C1

Sep 2001

NEW

ITEM

IMA 603

T50227

L50639

M51203

S19300-2

S51723-1

T10728-100

S10433-1

T10728-26

T12287-2

M50879-16

S8025-17

L50638

S51661-1

S9225-36

M51395

T51098

ITEMS NOT SHOWN

PART NO.

Use only the parts marked “X” in the column under the heading number called for in the model index page.

PART NO.

L50650

S51590-4

S51238

S51378-4

S51600-2

S9225-26

L50634-1

S9262-56

M51401

L50646-1

Ref: AP207-D

L50637

M51198

S9225-36

S51737-1

T51115

M51390

QTY.

4

1

1

1

1

4

4

4

2

4

1

1

2

1

1

1

1

1

2

2

2

2

2

2

1

4

4

1

2

1

1

2

2

8

1

1

1

4

4

1

1

1

2

1

1

1

1

QTY.

1 2 3 4 5 6 7 8 9 x x x x x x x x x x x x x x x x

X x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

1 2 3 4 5 6 7 8 9 DESCRIPTION

Wraparound assembly:

Cover and hinge assembly

Lock

Right panel

Left panel

Top left panel

Middle left panel

Low left panel

Door bumper

Wire feeder mounting

M51398

S21033

L50640

L50641

L50662

L50664

L50663

T14882

M12206


1

1

1

1

1

1

1

1

1 x x x x x x x x x

Page 25

Front Panel Assembly

Operative:

Supersedes:

AP-207-D

Sep 2001

NEW


# Indicates a change this printing.

* Items not illustrated.

Recommended Spare Parts are highlighted in bold

Nut, bolt and washer sizes are given so they may be procured locally.

ITEM DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

Welded front panel

Nameplate

Screw

Arc voltage range selector knob

Switch 3 positions

Arc voltage control knob

Switch 10 positions

Power Switch

White Light

Orange Light

Output connector

Screw

Amphenol plug (4 contacts)

Screw

Louver

Screw

Mounting

Digital display selector

Meter Option

Volt-ammeter PC board

Shunt (Not shown)

Operative:

Supersedes:

AP-207-D1

Sep 2001

NEW


PART NO.

M51394

G10334-7

S8025-92

T10491-100

S51715-6

T10491-100

S51715-5

T10800-4

T51088

T51089

M13896-3

S9225-8

S12021-18

S8025-73

G2016

S8025-78

M51278

T10800-4

M51397-1

S51776-1

QTY.

1

1

4

1

1

3

6

1

1

1

1

1

1

1

1

1

1

6

1

1

1 2 3 4 5 6 7 8 9 x x x x x x x x x x x x x x x x x x x x


Wiring Diagram


AP-207W

Operative: March 2000

Supersedes: NEW


Operative:

Supersedes:

AP-56

May 2001

NEW

REDI-MIG 4D Remote

KA1435

Model Index

NUMBERS IN THE TABLE BELOW INDICATE WHICH

COLUMN TO USE IN EACH PARTS LIST FOR EACH

INDIVIDUAL CODE NUMBER.

DO NOT attempt to use this Parts List for machine if its code number is not listed. Contact the Service Department for any code numbers not listed. (Only those suffixes which require distinction from the basic codes are shown.)

PARTS

LIST

TITLES

PARTS LIST

NO.

CODE NO.

1568

AP-56-C

1

AP-56-D AP-56-W

1 1

AP-49-C

2

Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REDI-MIG 325

IMA 603

# Indicates a change this printing


Panel Assembly

Operative:

Supersedes:

AP-56C

May 2001

NEW

4

45

54

44

54

56

45

26

2

9

7

51

24

46

16

17

18

44

14 40 51

43

29

20

11 15 21 40 51

42

28

1

19

34

37

49

41

45

49

46

3

29

45

46

46

23

10 12 39 50

33

25

38

53 31

55

30

45

5

NA

46

NA

NA

22 35 36 53

N.B.

45

12 27 39 50

46

6

32

8 13 52 57

N.A.

Page 30 REDI-MIG 455 Remote

AG 1412-1

(A14-4-00)

IMA 603

23

24

25

26

27

18

19

20

21

22

28

29

30

31

13

14

15

16

17

6

7

8

9

10

11

12

46

47

48

49

50

41

42

43

44

45

51

52

53

54

55

56

57

36

37

38

39

40

32

33

34

35






3

4

1

2

5

Base, Front & Rear

Door & Roof Assembly

Bulkhead

Side Panel

Harness Assembly includes

Wirefeed Pot

PCB Connector

Connection Cable Assembly

Euro Gun Adapter

3 /

16

” UNC x 3 /

4

” R.H. Screw

1 /

4

” UNC x 1” Hex Screw

5 /

16

” UNC x 3 /

4

” Hex Screw

M6 x Hex Nut

5 /

16

” UNC Hex Nut

3 /

16

” UNC Hex Nut

1 /

4

” UNC Hex Nut

M6 Hex Nut

Sleeving - Gun Trigger

Sleeving - Drive Motor

Drive Motor

Spool Post Assembly

4 Wheel Drive Plate Assembly

Insul Tube/Washer (Supplied/AM3391-8)

Solenoid Valve 42V

Nameplate

Bulkhead Support

Motor Control PCB / Burnback Header

Rubber Buffer

Vibro Insulator

Drive Plate Insulation

Magnetic Catch

DPDT Toggle Switch (Sprung)

Burnback Pot Assembly includes

Burnback Pot

PCB Connector

Cable Tie

Cable Tie

1 /

8

” dia Rivet

1 /

4

” NPT1 /

4

” Tube Straight Barb

1 /

4

” NPT1 /

4

” Tube Elbow Barb

Code & Serial Decal (Typed)

Rivnut #8-32 x .25”

5 /

16

” Springwasher

1 /

4

” Springwasher

Handle

Drive Roll, Cap & Screw

Brass Nut M12

Knob

S/T Screw Hex

Terminal .25 Recp 18-22ga

Terminal .25 Recp 14-16ga

Terminal .25 Tab 14-16ga

3 /

8

” x 1” T/C Screw

5 /

16

” Flatwasher

1 /

4

” Flatwasher

3 /

16

” Flatwasher

8ga x .32” Sems Screw

Insulation

SPDT Toggle Switch

Fastener Button

3 /

16

” Internal Starwasher

Operative:

Supersedes:

AP- 56-C1

May 2001

NEW


PART NO.

AG1410-1

AG1411-1

AL2648-1

AL2650-1

AL2652-1

AS4212-2

AT4045

AL2656-1

AM3025-2

AM3185

AM3387SP

AM3391SP

AM3391-1s

AM3399-1

AM3572-2

AM3577

AS4212-5SP

AS4404-1

AS4404-3

AS4435

AS4554

AS4706

AS4711

T10812-40

AS4212-7

AT3895-1T

AT3937

M15446

S18425-1

S8025-91

S8053-10

S8053-132

S8053-134

T10082-27

T12792-1

T13562

T14659-1

QTY.

1

1

2

2

1

1

2

1

1

1

1

1

1

1

4

1

1

1

2

1

2

3

2

1

1

1

3

1

2

5

1

1

1

1

1

1

1

1

1

4

1

2

1

10

2

6

1

1

1

2

5

1

1

3

3

16

1

1

4

5

5

1 2 3 4 5 6 7 8 9 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x


NOTES


Wiring Diagram

4D Remote

Operative:

Supersedes:

AP- 56W

May 2001

NEW


Wire Drive Assembly

Operative:

Supersedes:

AP-56-D

NEW

17

18

16a 16

15

14

13 10,11,12

9

1

2

3 4

5,6,7,8







15

16

16a

17

18

11

12*

13

14

7*

8*

9

10

3

4

5

6

1

2

Motor & Gearbox

Idle Roll Assy (R/H)

Inlet Guide

Wire Guide Tube

Gear Wheel

Fixing Cap

Parallel Key

Spacer

Drive Plate

Main Drive Gear

Fixing Cap

Woodruff Key

Screw M4x212

Middle Wire Guide

Screw M6x6

Euro Adapter Assy includes

Plastic Insulator

Calibrated Fixing Arm Assy

Idle Roll Assy (L/H)

Operative:

Supersedes:

AP-56-D1

NEW


PART NO.

AM3185

T07653R

018018

018019

022017

AM3391-1R

39250-044008

020004

024001

022016

022002

AM3391-1U

24890-040012

022015

07800-050006

AT3025-2

AM3025A2

T0760

T07653L

QTY.

x

1

1

1

1

1

1

1

1

1

1

2

8

1

1

2

2

1

1

1 2 3 4 5 6 7 8 9 x x x x x x x x x x x x x x x x x x x

CONSUMABLE ITEMS

OPTIONAL DRIVE ROLLS

0.8-0.9mm Solid Steel



0.8-1.0mm Aluminium

0.9-1.2mm Aluminium

0.8-1.0mm Flux Cored



AS4449-11

AS4449-8

AS4449-2

AS4449-5

AS4449-12

AS4449-3

AS4449-13

AS4449-4


REDI-MIG Torch 2 & 4 Consumables

AP-49C

Operative: May 2001

Supersedes: NEW

REDI-MIG Torch 2 & 4 Assembly


Operative:

Supersedes:

AP-49-C1

May 2001

NEW

12

13

14

15

16

8

9

10

11





ITEM DESCRIPTION PART NO.

2

3

3

4

4

1

1

2

5

5a

6

7

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Gas Hose Nipple

Gas Hose Nipple

Torch Head 45°

Torch Head 45°

Swan Neck Boot

Swan Neck Boot

Torch Head 60º

Torch Head 60º

Gas Diffuser

Gas Diffuser

Gas Diffuser

Steel, S/Steel and Flux Cored

Contact Tip ø 0.6

Contact Tip ø 0.8

Contact Tip ø 0.8

Contact Tip ø 0.9

Contact Tip ø 0.9

Contact Tip ø 1.0

Contact Tip ø 1.0

Contact Tip ø 1.2

Contact Tip ø 1.2

Contact Tip ø 1.4

Contact Tip ø 1.6

Aluminium

Contact Tip ø 0.9

Contact Tip ø 0.9

Contact Tip ø 1.0

Contact Tip ø 1.0

Contact Tip ø 1.2

Contact Tip ø

Coarse Thread Insulator

Gas Nozzle ø 13

Gas Nozzle ø 16

Gas Nozzle ø 19

Gas Nozzle ø 9.5

Gas Nozzle ø 13

Gas Nozzle ø 16

Gas Nozzle ø 19

Bushing Insulator

Bushing Insulator

Adjustable Gas Nozzle ø 13





Complete Handle Assembly

Long Tigger Swt

Female Trigger Connector

Hose Clamp 25mm

Hose Clamp 50mm

Adjusting Block Clamp

Adjusting Block Clamp

Rear End Assembly Complete

Male Trigger Connector

Gun Plug Nut

Female Connector

Euro Adapter

Liner Nut

Steel Liner 0.8-1.0

Steel Liner 0.9-1.2

Steel Liner 1.0-1.2

Steel Liner 1.0-1.2

Steel Liner 1.2-1.6

Steel Liner 1.6-2.0

Teflon Liner 0.9-1.2

Teflon Liner 1.2-1.6

ME62

ME20

MD3-06

MD3-08

MD4-08

MD3-09

MD4-09

MD3-10

MD4-10

MD3-12

MD4-12

MD4-16


INDUSTRY REF

QY62N

QY64N

QY62A-45

QY64A-45

QY72A

QY74A

QY62A-60

QY64A-60

QY52FN

QY54A

QY52

QY14-23

QY14-30

QY14H-30

QY14-35

QY14H-35

QY14-45

QY14H-45

QY14H-52

QY14H-116

QTY.

1 pkt of 10

“

“

“

“

“

“

“

“

“

“

1 x x x x

2

1

1

1

1

1

1

1

1 x x x x

1 pkt of 10 x

“

1 x x x x x x x x x x

MD3-09A

MD4-09A

MD3-10A

MD4-10A

MD3-12A

MD4-12A

MQ130

MQ131

MC235

MT75

BX24

QY34CT

QY24CT-50-S

QY24CT-62-S

QY24CT-75-S

QY23-37

QY23-50

QY23-62

QY23-75

QY32

QY34A

QY22-50

QY24A-50

QY22-62

QY24A-62

QY24A-75

EA291

EA293

MT70

MT72

MT77

BX200

2

2

2

2

1

2

QY174X-1

BX206

QY174X-1

1

2

1

QY174X-1C 1

GM11 QY42-3545-15

GM826

GM12

QY44-4045-15 1

QY44-3545-15

QY42-4045-15

GM13 QY44-116-15

QY44-56Y-15 1

GM230

GM231

QY42N-3545-15

QY44N-116-15 x x x x x

1

1 x

1

“

“

“

“

“

“

“

“

“

“

“

“

“ x x x x x x

“

1

1

1 pkt of 10 x

“ x x x x x

“

1

1

“

“

2 x x x x x x x x x x x x x x x x x x x x x x x x x x

1

1

1 x x x x x x x x x x x x x x x

x x x x

3 4 5 6 7 8 9


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