Lincoln Electric REDI-MIG 210c, REDI-MIG 250c, REDI-MIG 250s, REDI-MIG 325c, REDI-MIG 325s Operator's Manual
IM6015
REDI-MIG® 210c, 250c, 250s, 325c, 325s
Page 1
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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.
REDI-MIG® 210c, 250c,
250s, 325c & 325s
Operator’s Manual
IM6015
October 2008
Lincoln Electric® Australasia
Part No. Code Description Volts
K32048-1 70169 REDI-MIG® 210c 240
K32049-1 70170 REDI-MIG® 250c 240
K32049-2 70171 REDI-MIG® 250s 240
K32050-1 70172 REDI-MIG® 325c 415
K32050-2 70173 REDI-MIG® 325s 415
This manual applies to
Page 2
REDI-MIG® 210c, 250c, 250s, 325c, 325s
IM6015
ARC WELDING SAFETY PRECAUTIONS 3
WELDING, EMF & PACEMAKERS 5
INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY 6
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 14
Section 4 WELDING 17
4.1 Changing Electrode Size and Type 17
4.2 Adjusting Spool Tension 17
Section 5 LEARNING TO WELD 17
5.1 The Arc-Welding Circuit 17
5.2 The Self-Shielded (Gasless) FCAW Welding Arc 18
5.3 The 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
5.13 Fillet Welds 22
5.14 Welding in the Vertical Position 22
5.15 Vertical-Up and Overhead Welding 22
5.16 Vertical-Down Welding 22
5.17 Troubleshooting Welds 22
Section 6 MAINTENANCE 23
6.1 Routine Maintenance 23
6.2 Gun and Cable Maintenance 23
6.3 Gun Tips and Nozzles 23
6.4 Input Lead 23
6.5 Liner Removal, Installation and Trimming Instructions
for LINC Gun® 240 & 360 Torch 24
Section 7 ACCESSORIES 24
Section 8 GROUND TEST PROCEDURE 24
Section 9 TROUBLESHOOTING 26
PARTS LISTS REDI-MIG
®
210c, 250c, 250s, 325c, 325s 27
WIRING DIAGRAM REDI-MIG
®
210c, 250c, 250s, 325c, 325s
PARTS LISTS REDI-MIG
®
4s Remote
WIRING DIAGRAM REDI-MIG
®
4s Remote Wire Feeder
INDEX
IM6015
REDI-MIG® 210c, 250c, 250s, 325c, 325s
Page 3
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
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.
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.
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 refer to AS 1674 .1 & .2 (latest editions).
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.
ELECTRIC SHOCK can kill
FUMES AND GASES
can be dangerous
ARC RAYS can burn
WELDING SPARKS can
cause fire or explosion
Page 4
REDI-MIG® 210c, 250c, 250s, 325c, 325s
IM6015
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.
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. Earth the equipment in accordance with the SAA
Wiring Rules and the manufacturer’s recommendations.
7. 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.
h. To avoid scalding do not remove the
radiator pressure cap when the engine is
hot.
CYLINDER may explode
if damaged
FOR ELECTRICALLY
powered equipment
FOR ENGINE
powered equipment
HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE
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
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.
For more detailed information it is strongly recommended that you review copies of “Safety in Welding and Allied processes - AS 1674.1 &
.2” and WTIA Technical Note 7 – TN07. Australian Standards are available from SAI Global – www.saiglobal.com and WTIA publications
are available from the Welding Technology Institute of Australia – www.wtia.com.au.
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