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Lincoln Electric REDI-MIG 325 Remote, Operating Manual

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Lincoln Electric REDI-MIG 325 Remote Operating Manual Download Page 7

IMA 599B

REDI-MIG 325

Page 7

Page

Section 1

INSTALLATION

8

1.1

Location

8

1.2

Connection to Mains Supply

8

1.3

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

9

1.4

Gun and Cable Installation

9

1.5

Output Polarity Connection

9

Section 2

OPERATING INSTRUCTIONS

10

2.1

Duty Cycle

10

2.2

Control Panel

10

Section 3

SETTING UP FOR WELDING

11

Section 4

WELDING

13

4.1

Changing Electrode Size and Type

13

4.2

Adjusting Spool Tension

13

Section 5

LEARNING TO WELD

13

5.1

The Arc-Welding Circuit

13

5.2

The Self-Shielded (Gasless) FCAW Welding Arc

14

5.3

The GMAW (MIG) Welding Arc

14

5.4

Process Selection

14

5.5

Common Metals

14

5.6

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

14

5.7

Welding Techniques for the 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

Section 6

MAINTENANCE

19

6.1

Routine Maintenance

19

6.2

Gun and Cable Maintenance

19

6.3

Gun Tips and Nozzles

19

6.4

Input Lead

19

6.5

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

20

Section 7

ACCESSORIES

20

Section 8

GROUND TEST PROCEDURE

20

Section 9

TROUBLESHOOTING

21

PARTS LISTS REDI-MIG 325 Remote

23

WIRING DIAGRAM REDI-MIG 325 Remote

30

PARTS LISTS REDI-MIG 4D Remote

31

WIRING DIAGRAM REDI-MIG 4D Remote Wire Feeder

35

WIRE DRIVE ASSEMBLY

36

PARTS LIST REDI-MIG 360 TORCH

38

INDEX

Summary of Contents for REDI-MIG 325 Remote

Page 1: ...oln 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 REDI MIG 325 Remote Semi Automatic ...

Page 2: ... 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 confor...

Page 3: ... 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 start...

Page 4: ...ing 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 or a...

Page 5: ...lding 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 recommendat...

Page 6: ...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 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 se...

Page 7: ...or the 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 ...

Page 8: ...5 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 meters a spot timer gas purge facilities wire inch bu...

Page 9: ...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 diag...

Page 10: ...rigger 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 e WARN...

Page 11: ... standard drive rolls for other types and sizes are available as spare parts see table on page 12 4 A work return cable and clamp supplied 5 Normal welding accessories including helmet or hand shield with 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...

Page 12: ... Part Part No Part Part No Part Part No Part Part No Contact Tip 0 8mm 340P081262 Contact Tip 0 8mm 340P081262 Contact Tip 0 8mm 340P081262 Contact Tip 0 9mm 340P091262 Contact Tip 0 9mm 340P091262 Contact Tip 0 9mm 341P091262 Contact Tip 0 9mm 340P091262 Contact Tip 1 0mm 340P101262 Contact Tip 1 0mm 340P101262 Contact Tip 1 0mm 341P101262 Contact Tip 1 0mm 340P101262 Contact Tip 1 2mm 340P121262...

Page 13: ... 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 3 0 8 1 0 Cored Wire AS4449 13 0 9 1 2 Cored Wire AS4449 4 1 2 1 6 Cored Wire Available Drive Rolls Section 5 LEARNING TO WELD ...

Page 14: ...s 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 a...

Page 15: ...s 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 tip...

Page 16: ...lamp 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 ...

Page 17: ... face and eyes 3 Depress gun trigger hold gun so contact tip to work distanceIsabout 10 12 mm andthe gunisatproper 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 flat plat...

Page 18: ...al 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 that ...

Page 19: ... 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 over temperature 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 contact tip f...

Page 20: ...le and gas diffuser 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 contact tip holder 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 at the feeder end of the cable and pull the liner out of the cable 4 Insert a new u...

Page 21: ... 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 s...

Page 22: ...re 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 Boards if no fault is detected in tr...

Page 23: ...ICATE 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 General Assembly Front Panel Assembly Cover Panels Wiring Diagram PARTS LIST TITLES Operating Manual...

Page 24: ...y Page 24 REDI MIG 325 IMA 599B A C Mounts Ite m 106 E Mounts Ite m 106 1 50 21 18 20 4 4 6 7 3 12 11 14 13 21 10 5 5 8 19 9 DETAIL A 1 2 1 17 15 16 AP 58C Operative Nov 2003 Supersedes May 2001 Ref AG1417 4 A13 10 99 ...

Page 25: ...494 6 1 x x 10 Push Nut AT2876 1 2 x x x x 11 8 Wheel AS4071 1 2 x x x x 12 Base Assembly AG1418 1 x x x x 13 Input Lead Assembly AS4303 1 x x x x 14 Cord Strain Relief AT3764 1 1 x x x x 15 5 Blade Fan AM3285 1 1 x x 16 Dual Fan Shroud AM3449 1 x x 16 Dual Fan Shroud AM3449 2 1 x x 17 Fan 4 Blade AM3285 1 x x x x 18 Fan Motor AS4233 1 2 x x x x 19 Rectifier 3ph 330A AL2480 1 x x x x 20 Choke Asse...

Page 26: ...General Assembly Page 26 REDI MIG 325 IMA 599B B A 13 12 11 2 3 1 4 6 8 9 10 11 7 DETAIL A 2 7 1 4 8 6 5 AP 58 C2 Operative Nov 2003 Supersedes May 2001 Ref AG1417 4 A13 10 99 DECAL PLACEMENT ...

Page 27: ...x Main Transformer Assembly 415V AL2494 5 1 x x Main Transformer Assembly 380V AL2494 6 1 x x Use only the parts marked X in the column under the heading number called for in the model index page AP 58 C3 Operative Nov 2003 Supersedes May 2001 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 15 Power Lead Harness AL2611 1 x 16 Meter Harness AM3605 1 x 17 Roof Rubber Mat AM3606 1 x 19 Argon Regulator...

Page 28: ...AS4460 1 1 x x 4 Nameplate REDI MIG 325 Remote AL2691 4 1 x x 5 Voltmeter 0 50V DC AM3397 1 1 x x 6 Ammeter 0 400A DC am3398 1 1 x x 7 Fastener Button T14659 1 4 x x 8 Bushing 41 3 i d T12380A1 1 x x 9 Lead 43A Temp Lt to Rect Thermo AM3040B570 1 x x 10 Resistor Diode Lead Assembly AS4453 5 1 x x Use only the parts marked X in the column under the heading number called for in the model index page ...

Page 29: ... Screw Bright S9225 8AZ 2 x x 5 L H SIDE PANEL AL2684 1 x x 3 16 S T Screw S8025 91 6 x x 1 4 S T Screw Black S9225 68 1 x x 6 Roof Door Assembly AL2689 1 x x 3 16 S T Screw S8025 91 4 x x 7 Bulkhead AL2690 1 x x 8 Rubber Mat AM3606 1 x x Use only the parts marked X in the column under the heading number called for in the model index page AP 58 E1 Operative May 2001 Supersedes NEW Recommended Spar...

Page 30: ...W Operative May 2001 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 AM3596 4 A13 10 99 ...

Page 31: ...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 Assembly Wire Drive Assembly Wiring Diagram PARTS LIST TITLES Operating Manual REDI MIG 325 IMA 599B Indicates a change this printing AP 56 Operative Nov 200...

Page 32: ...2 REDI MIG 325 IMA 599B Panel Assembly AP 56C Operative Nov 2003 Supersedes May 2001 10 8 8 9 5 20 1 11 12 14 15 16 21 23 22 22 9 29 28 42 26 25 24 4 13 6 6 2 30 27 6 17 18 15c 4 19 6 7 3 1 AG 1412 1 A14 4 00 ...

Page 33: ... x 32 Sems Screw T10082 27 6 x 16 Vibro Insulator AS4404 3 4 x 17 Bulkhead Support AM3577 1 x 18 Motor Control PCB Burnback Header AS4212 5SP 1 x 19 Rivnut 8 32 x 25 AT3937 4 x 20 Burnback Pot Assembly includes AS4711 1 x 20a Burnback Pot T10812 40 1 x 20b PCB Connector AS4212 7 1 x 21 Code Serial Decal Typed NSS 1 x 22 3 8 x 1 T C Screw 2 x 23 Handle M15446 1 x 24 Bulkhead AL2648 1 1 x 25 Spool P...

Page 34: ...Page 34 REDI MIG 325 IMA 599B NOTES ...

Page 35: ... Operative May 2001 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 AM3596 5 A13 10 99 ...

Page 36: ...Page 36 REDI MIG 325 IMA 599B 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 Ref AM3391 ...

Page 37: ...012 1 x 14 Middle Wire Guide 022015 1 x 15 Screw M6x6 07800 050006 x x 16 Euro Adapter Assy includes AT3025 2 1 x 16a Plastic Insulator AM3025A2 1 x 17 Calibrated Fixing Arm Assy T00760 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 Alumi...

Page 38: ...Page 38 REDI MIG 325 IMA 599B REDI MIG 360 Torch AP 49E Operative Nov 2003 Supersedes May 2001 ...

Page 39: ...004 160 Spring support small 600P102099 162 Adapter support 701P001045 163 Screw M4 x 6 100P008401 164 Adapter Nut 701P001013 170 ESG connector complete 701P001002 174 O Ring 365P100040 175 Trigger wire connector female 375P000003 176 Liner positioning nut M10 x 1 701P002005 180 Liner blue 3m 324P154534 1 5 x 4 5mm for wire 0 8 1 0mm 180 Liner blue 4m 324P154544 1 5 x 4 5mm for wire 0 8 1 0mm 180 ...

Page 40: ...he operation non operation or malfunction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facility about any defect claimed under Lincoln s warranty Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorised Service Facility WARRANTY REPAIR If Lincoln or Lincoln ...

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