Lincoln Electric REDI-MIG 455 Remote, Operating Manual

Page 1: ...tric 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 IMA 603 OPERATING MANUAL Part No Code Descr...

Page 2: ...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 con...

Page 3: ...ety 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 st...

Page 4: ...elding 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 bi polar or designed to filter out such interference For a welder o...

Page 5: ...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 recommend...

Page 6: ...erence 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...

Page 7: ...he Self Shielded Gasless FCAW Process 15 5 8 Machine Set Up for the GMAW MIG and Gas Shielded FCAW Processes 16 5 9 Welding Techniques for the GMAW MIG Process 16 5 10 Joint Types and Positions 17 5 11 Butt Welds 17 5 12 Penetration 17 5 13 Fillet Welds 18 5 14 Welding in the Vertical Position 18 5 15 Vertical Up and Overhead Welding 18 5 16 Vertical Down Welding 18 5 17 Troubleshooting Welds 18 S...

Page 8: ...or disconnecting cables or other equipment WARNING HIGH VOLTAGE can kill Only qualified personnel should install or service this equipment 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 provide...

Page 9: ... 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 1 5 Output Polarity Connection 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 c...

Page 10: ...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 e Inductance Settings Th...

Page 11: ...th suitable lens gloves etc 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 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 ...

Page 12: ...m GM226 Liner Teflon 0 9 1 2mm GM230 Liner 0 9 1 2mm GM226 Drive Ro ll 1 2 1 6mm GM231 Aluminium Feeding Kit KA1440 3 Flux Cored Feeding Kit KA1441 3 PLATE THICKNESS 0 9mm 1 6mm 3 0mm 5 0mm 8 0mm 21 gauge 16 gauge 10 gauge 6 gauge 1 gauge PROCESS WELDING WIRE SHIELDING GAS 0 032 1 16 0 134 0 203 0 300 Recommended Wire 0 9mm Dia MIG Solid Steel Wire Argon CO 2 blend Aa 3 Af 5 Bb 7 Bi 12 Cb 16 DC Li...

Page 13: ...ble for the wire to arc to the case Any wire overrun should be avoided WARNING Part No Size mm Use with AS4449 9 0 6 0 8 Solid Wire AS4449 11 0 8 0 9 Solid Wire AS4449 8 0 9 1 2 Solid Wire AS4449 2 1 0 1 2 Solid Wire AS4449 5 0 8 1 0 Aluminium Wire AS4449 12 0 9 1 2 Aluminium Wire AS4449 6 1 2 1 6 Aluminium Wire AS4449 3 0 8 1 0 Cored Wire AS4449 13 0 9 1 2 Cored Wire AS4449 4 1 2 1 6 Cored Wire A...

Page 14: ...e 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 spa...

Page 15: ... has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 10 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 ...

Page 16: ...p 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 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 ill...

Page 17: ...ct 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 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 f...

Page 18: ...rtical 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 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 t...

Page 19: ...rmostats 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 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 contac...

Page 20: ...her gun unless it can meet the liner cutoff length requirement 1 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 2 Remove the gas diffuser from the gun tube 3 Lay the gun and cable out straight on a flat surface Loosen the liner nut cap located in the brass connector a...

Page 21: ...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 c...

Page 22: ...s 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 Replace PCB Refer PCB replacement procedure on page 19 Allow machine to cool down and reduce on time and or wire feed speed Repair Refer Procedure for Replacing PC Boa...

Page 23: ...L 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 General Asssembly Front Panel Assembly Wiring Diagram PARTS LIST TITLES Operating Manual REDI MIG 455 IMA 603 Indicates a change this printing AP 207 Operative Sep...

Page 24: ...Page 24 REDI MIG 455 Remote IMA 603 General Assembly AP 207C Operative Sep 2001 Supersedes NEW ...

Page 25: ...Relay PC Board M51203 1 x Mounting Clip S19300 2 4 x 15 Fuse Holder S51723 1 1 x Fuse 2 Amp T10728 100 1 x 16 Fuse Holder S10433 1 1 x Fuse 5 Amp T10728 26 1 x 17 Circuit breaker T12287 2 1 x 18 Auxiliary transformer M50879 16 1 x Screw S8025 17 4 x 19 Middle Panel L50638 1 x 20 Coupling connector 230 400V 415V S51661 1 1 x Screw S9225 36 2 x 21 Contactor M51395 1 x 22 Snap Bushing T51098 1 x Use ...

Page 26: ...Page 26 REDI MIG 455 Remote IMA 603 Front Panel Assembly AP 207 D Operative Sep 2001 Supersedes NEW ...

Page 27: ...ht T51089 1 x 8 Output connector M13896 3 3 x Screw S9225 8 6 x 9 Amphenol plug 4 contacts S12021 18 1 x Screw S8025 73 4 x 10 Louver G2016 1 x Screw S8025 78 1 x Mounting M51278 1 x 11 Digital display selector T10800 4 1 x Meter Option 12 Volt ammeter PC board M51397 1 1 x Shunt Not shown S51776 1 1 x Use only the parts marked X in the column under the heading number called for in the model index...

Page 28: ...emote AP 207W Operative March 2000 Supersedes NEW Note This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosed panels Ref M51396 3 ...

Page 29: ... 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 General Assembly Wire Drive Assembly Wiring Diagram PARTS LIST TITLES Operating Manual REDI MIG 325 IMA 603 Indicates a change this printing AP 56 Operative May 2001 Supersedes NEW REDI MIG Torches ...

Page 30: ...31 23 55 30 5 NA NA NA 22 36 35 50 39 12 27 32 33 34 37 41 49 49 44 17 16 51 40 14 43 29 20 21 51 40 42 1 19 29 3 46 46 45 46 45 46 46 45 45 46 8 2 13 52 57 N A 18 28 15 11 45 24 25 53 53 N B 26 7 38 6 45 10 12 39 50 56 AG 1412 1 A14 4 00 Page 30 REDI MIG 455 Remote IMA 603 ...

Page 31: ...ion AS4435 1 x 29 Magnetic Catch AS4554 2 x 30 DPDT Toggle Switch Sprung AS4706 1 x 31 Burnback Pot Assembly includes AS4711 1 x Burnback Pot T10812 40 1 x PCB Connector AS4212 7 1 x 32 Cable Tie 1 x 33 Cable Tie 2 x 34 1 8 dia Rivet 2 x 35 1 4 NPT 1 4 Tube Straight Barb 1 x 36 1 4 NPT 1 4 Tube Elbow Barb 1 x 37 Code Serial Decal Typed AT3895 1T 1 x 38 Rivnut 8 32 x 25 AT3937 4 x 39 5 16 Springwas...

Page 32: ...NOTES Page 32 REDI MIG 455 Remote IMA 603 ...

Page 33: ...W Note This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosed panels Ref AM3596 5 A13 10 99 IMA 603 REDI MIG 455 Remote Page 33 ...

Page 34: ...Wire Drive Assembly AP 56 D Operative NEW Supersedes 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 16a 17 18 Page 34 REDI MIG 455 Remote IMA 603 ...

Page 35: ... x 16 Euro Adapter Assy includes AT3025 2 1 x 16a Plastic Insulator AM3025A2 1 x 17 Calibrated Fixing Arm Assy T0760 1 x 18 Idle Roll Assy L H T07653L 1 x CONSUMABLE ITEMS OPTIONAL DRIVE ROLLS 0 8 0 9mm Solid Steel AS4449 11 0 9 1 2mm Solid Steel AS4449 8 1 0 1 2mm Solid Steel AS4449 2 0 8 1 0mm Aluminium AS4449 5 0 9 1 2mm Aluminium AS4449 12 0 8 1 0mm Flux Cored AS4449 3 0 9 1 2mm Flux Cored AS4...

Page 36: ...REDI MIG Torch 2 4 Consumables REDI MIG Torch 2 4 Assembly AP 49C Operative May 2001 Supersedes NEW Page 36 REDI MIG 455 Remote IMA 603 ...

Page 37: ...9 5 QY23 37 x x 13 Gas Nozzle ø 13 QY23 50 x x 14 Gas Nozzle ø 16 QY23 62 x x 15 Gas Nozzle ø 19 QY23 75 x x 16 Bushing Insulator MQ130 QY32 1 x Bushing Insulator MQ131 QY34A 1 x 17 Adjustable Gas Nozzle ø 13 QY22 50 1 pkt of 10 x Adjustable Gas Nozzle ø 13 QY24A 50 x 18 Adjustable Gas Nozzle ø 16 MC235 QY22 62 x Adjustable Gas Nozzle ø 16 QY24A 62 x 19 Adjustable Gas Nozzle ø 19 QY24A 75 x 20 Com...