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  IM6016 

REDI-MIG

®

 Plus 215C, 255C, 255S  

Page 5

WELDING, EMF & PACEMAKERS

All  welders  should  follow  safe  practices  that  minimise  their 

exposure to electric and magnetic fields (EMF).

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).

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.

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.

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.

Welders with pacemakers

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 

bi-polar or designed to filter out such interference.

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.

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.

Summary of Contents for REDI-MIG Plus 215C

Page 1: ...ncoln 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 Plus 215C 255C 255S Oper...

Page 2: ...e GMAW MIG Welding Arc 18 5 4 Process Selection 18 5 5 Common Metals 18 5 6 Machine Set Up for the Self Shielded Gasless FCAW Process 18 5 7 Welding Techniques for the Self Shielded Gasless FCAW Process 19 5 8 Machine Set Up for the GMAW MIG and Gas Shielded FCAW Processes 20 5 9 Welding Techniques for the GMAW MIG Process 20 5 10 Joint Types and Positions 21 5 11 Butt Welds 21 5 12 Penetration 21...

Page 3: ... 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 sh...

Page 4: ...e 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 appro...

Page 5: ...rc 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 bi polar or designed to filter out such interference For a weld...

Page 6: ...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 reco...

Page 7: ...UALITY 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 leve...

Page 8: ...family is the latest development in step controlled MIG welding machines designed and built by Lincoln Electric Lincoln Electric s new REDI MIG Plus family comprises of three models in both compact and separate wire feeder The REDI MIG Plus 215C 255C and 255S are for 240 volt supply Excellent arc characteristics are provided for gas shielded and self shielded welding within the respective machine ...

Page 9: ...istive 1 5 Output Polarity Connection 215C and 255C only The electrode cable is located between output terminals The electrode cable is connected to the required output terminal on the front of the REDI MIG Plus 215C and 255C The gun polarity can be changed by placing the electrode cable to the required output terminal eg for electrode ve connect the electrode cable to the ve output stud Connect t...

Page 10: ... motor is dynamically braked to minimise wire over run after welding has ceased 4 TORCH CONNECTION Euro torch connection 5 ARC VOLTAGE CONTROL The output voltage is controlled by rotary switch This is located on the separate wire feeder of the REDI MIG 255S The approximate weld voltages for the rotary switch postions for the 215C 255C and 255S are above 6 AMPERAGE AND VOLTAGE METER Digital meter d...

Page 11: ...or 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 10 Output Terminals Dinse connection used to connect ele...

Page 12: ...priate wire onto the spool so that it turns clockwise as the wire is fed 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 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...

Page 13: ...shield FCAW 77 Argon 23 CO 2 SuperGlaze 5356 UltraMag S6 EasyMIG S6 100 CO 2 100 Argon Innershield FCAW No Gas Required No Gas Required AUS 1300 LINCOLN NZ 0800 728 720 CONSUMABLE PARTS LINC Gun LG240G REDI MIG PLUS 215C 255C Contact Tip M6 0 6mm LG240G KP10440 06 Contact Tip M6 0 8mm LG240G KP10440 08 Contact Tip M6 0 9mm LG240G KP10440 09 Contact Tip M6 1 2mm LG240G KP10440 12 Contact Tip M6 0 9...

Page 14: ...2 4 5 4 3 6 1 6mm 3 0mm 5 0mm 8 0mm 100 CO 2 100 Argon Innershield Æ FCAW 77 Argon 23 CO 2 SuperGlaze Æ 4043 5356 UltraMag Æ S6 EasyMIG ô S6 100 CO 2 100 Argon No Gas Required No Gas Required Innershield Æ FCAW NR211MP NR212 DC Outershield Æ 71 CX FCAW DC CONSUMABLE PARTS LINC GUN LG240G REDI MIG PLUS 255S Contact Tip M6 0 6mm LG240G KP10440 06 Contact Tip M6 0 8mm LG240G KP10440 08 Contact Tip M6...

Page 15: ...2 1 0 1 2 Solid Redimig Plus 215 255C KP61015 0912R 0 9 1 2 Cored Redimig Plus 215 255C KP61015 16R 1 2 1 6 Cored Redimig Plus 215 255C KP61240 08 0 6 0 8 Solid Redimig Plus 255S KP61240 0912 0 9 1 2 Solid Redimig Plus 255S KP61240 16 1 2 1 6 Solid Redimig Plus 255S KP61240 0912A 0 9 1 2 Aluminium Redimig Plus 255S KP61240 12A 1 0 1 2 Aluminium Redimig Plus 255S KP61240 0912R 0 9 1 2 Cored Redimig...

Page 16: ...ing 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 wil...

Page 17: ... arc 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 cont...

Page 18: ... 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 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 Corre...

Page 19: ... 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 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 ...

Page 20: ...al 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 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 eno...

Page 21: ...ally 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 from the gu...

Page 22: ...e 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 untrimmed liner into the connector end of the cable 5 Fully seat the liner bushing into the Euro connector Tighten the liner nut cap on the brass cable connector The contact tip holder at this time should not be ins...

Page 23: ...e life of a particular machine so details of this procedure may need to be adjusted to suit these modifications For prompt service contact your local authorised Lincoln Electric Field Service Shop The insulation resistance values listed below are from Australian Standard AS60974 1 1 Disconnect input cable from power supply 2 Disconnect gun assembly and work cable 3 Remove the side panel from power...

Page 24: ...nual 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 tigh...

Page 25: ...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 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...

Page 26: ... any way liable for the 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 I...

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