Lincoln Electric Compact 220 User manual

OPERATING MANUAL OF THE WELDING SEMI-AUTOMATIC
EN ISO 9001
CERTCERT
TUVTUV
..
LINCOLN
ELECTRIC
R
Compact 220
COMPACT220

BESTER S.A. ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
and has been designed in conformance with the following norms:
und in Übereinstimmung mit den nachstehenden Normen hergestellt wurde:
i ¿e zosta³o zaprojektowane zgodnie z wymaganiami nastêpuj¹cych norm:
73/23/CEE, 93/68/CEE, 89/366/CEE, 92/31/CEE
conforms to the following directives:
dan folgenden Bestimmungen entspricht:
spe³nia nastêpuj¹ce wytyczne:
Compact 220 s/n
Declares that the welding machine:
Erklärt, daß die Bauart der Maschine:
Deklaruje, ¿e spawalnicze Ÿród³o energii:
Thank You
Declaration of confirmity
Konformitätserklärung
Deklaracja zgodnoœci
BESTER S.A.
EN 50199, EN 60974-1
for selecting a QUALITY product by Lincoln Electric.
We want you to take pride in operating this
Lincoln Electric Co. product Compact 220 as much
pride as we have in briging this product to you!
Pawe³ Lipiñski
Operational Director

Table of Contents
Safety
Features
4
10
11
12
13
14
16
16
16
17
19
18
20
15
21
22
21
23
30
29
24
25
32
General Information and Warning
Front Panel of the Compact 220
Rear Panel of the Compact 220
Trouble Shooting Guide
Preparation for Welding Works
Environmental Conditions
Information about the Producer
Connecting Shielding Gas
Inserting Electrode Wire and Braking Torque Adjustment
Technical Data
Care and Maintenance
Storage and Transportation
Static Characteristics of Compact 220
Spot Welding
Defects of Welding Seams
Plugging Compact 220 in
Installation of the Compact 220
Spare Parts List
Notes
Assembly of the Drive Roll of the Feeding Unit
Welding Parameters
Page 3

Safety
Warning!
Protect yourself and others from possible serious injury or death.
Keep children away. Pacemaker wearers should consult with
-In addition to the normal safety precautions, if welding must be per-
their doctor before operating.
Pay attention in handling the pieces being worked on, use ade-
quate tools to avoid burns can be caused by the overheating of
the piece during the operation of welding and/or cutting.
Be sure that all installation, maintenance, and repair procedures
are performed only by qualified individuals.
ELECTRIC SHOCK can kill
- 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.
- Insulate yourself from work and ground using dry insulation. Make sure
the insulation is large enough to cover your full area of physical contact
with work and ground.
formed under electrically hazardous conditions /in damp locations or
while wearing wet clothing; on metal structures such as floors, gra-
tings or scaffolds; when in cramped positions such as sitting, knee-
ling or lying, if there is a high risk of unavoidable or accidental contact
with the workpiece or ground/ use the following equipment:
* Semiautomatic DC Constant Voltage Wire/ Welder
* DC Manual /Stick/ Welder
* AC Welder with Reduced Voltage Control
- In semiautomatic or automatic wire welding, the electrode, electrode reel,
welding head, nozzle or semiautomatic welding gun are also electrical "hot".
- 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.
Page 4

ARC RAYS can burn
FUMES AND GASES can be dangerous
- Ground the work or metal to be welded to a good electrical /earth/ ground.
- Maintain the electrode holder, work clamp, welding cable and welding ma-
chine in good, safe operating condition. Replace damaged insulation.
- Never dip the electrode in water for cooling.
- 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.
- When working above floor level, use a safety belt to protect yourself from
a fall should you get a shock.
- 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 ANSI Z87. I stan-
dards.
- Use suitable clothing made from durable flame-resistant material to pro-
tect your skin and that of your helpers from the arc rays.
- Protect other nearby personnel with suitable non-flammable screening
and/or warn them to watch the arc nor expose themselves to the arc rays
or to hot spatter or metal.
- Welding may produce fumes and gases hazardous to health. Avoid brea-
thing 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 with electrodes
which require special ventilation such as stainless or hard facing or on
lead or cadmium plated steel and other metals or caotings which produce
highly toxic fumes, keep exposure as low as possible and below TLV
Page 5

WELDING SPARKS can cause fire or explosion
/Threshold Limit Values/ using local exhaust or mechanical ventilation.
In confined spaces or in some circumstance, outdoors, a respirator may
be required. Additional precautions are also required when welding on
galvanized steel.
- Do not weld in locations near chlorinated hydrocabron vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosogne, a highly toxic gas, and
other irritating products.
- Shielding gases used for arc welding can displace air and cause injury or
death. Always use enough ventilation, especially in confined areas, to in-
sure breathing air is safe.
- Read and understand the manufacturer's instructions for this equipment
and the consumables to be used, including the material safety data sheet
and follow your employer's safety practices.
- 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. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
- Where compressed gases are to be used at the job site, special precau-
tions should be used to prevent hazardous situations.
- When not welding, make certain no part of the electrode circuit is touch-
ing the work or ground. Accidental contact can cause overheating and
create a fire hazard.
- 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 vapors from substances inside.
Page 6

CYLINDER may explode if damaged
They can cause an explosion even though they have been "cleaned".
For information purchase "Recommended Safe Practices for the Prepa-
ration for Welding and Cuttig of Containers and Piping That Have Held
Hazardous Substances", AWS F4.1 from theAmerican Welding Society.
- Vent hollow castings or containers before heating, cutting or welding.
They may explode.
- Sparks and spatter are thrown from the welding arc. Wear oil free prote-
ctive garments such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when welding out of po-
sition or in confined places. Always wear safety glasses with side shields
when in a welding area.
- Connect the work cable to the work as close to the welding area as pra-
ctical. 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.
- 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.
- Always keep cylinders in an upright position securely chained to an under-
carriage or fixed support.
- 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.
Page 7

FOR ELECTRICALLY powered equipment
- Never allow the electrode, electrode holder or any other electrically "hot"
parts to touch a cylinder.
- Keep your head and face away from the cylinder valve outlet when open-
ing the cylinder valve.
- Valve protection caps should always be in place and hand tight except
when the cylinder is in use or connected for use.
- Turn off input power using the disconnect switch at the fuse box before
working on the equipment.
- Install equipment in accordance with the U.S.National Electrical Code,
all local codes and the manufacturer's recommendations.
- Ground the equipment in accordance with the U.S. National Electrical
Code and the manufacturer's recommendations.
- Do not add the fuel near an open flame welding arc or when the engine
is running. Stop the engine and allow it to cool before refueling 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.
- 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.
Page 8

ELECTRIC AND MAGNETIC FIELDS may be dangerous
- In some cases it may be necessary to remove safety guards to perform
required maintenance. Remove guards only when necessary and repla-
ce them when the maintenace requiring their removal is complete. Always
use the greatest care when working near moving parts.
- Do not put your hands near the engine fan. Do not attempt to override
- To prevent accidentally starting gasoline engines while turning the engi-
ne or welding generator during maintenance work, disconnect the spark
the governor or idler by pushing on the throttle control rods while the
engine is running.
plug wires, distributor cap or magneto wire as appropriate.
- To avoid scalding, do not remove the radiator pressure cap when the
engine is hot.
- Electric current flowing through any conductor causes localized Electric
and Magnetic Fields /EMF/. Welding current creates EMF fields around
welding cables and welding machines.
- EMF fields may interfere with some pacemakers, and welders having
- Exposure to EMF fields in welding may have other health affects which
- To minimize exposure to EMF fields all welders should:
a pacemaker should consult their physician before welding.
are now not know.
* Route the electrode and work cables together .
* Do not place your body between the electrode and work cables.
* Never coil the electrode lead around your body.
* Connect the work cable to the workpiece as close as possible.
* Do not work next to welding power source.
Page 9

General Information and Warning
- Do not install, operate or repair this equipment without reading this
Manual and the safety precautions contained throughout. Save this
Manual and keep it handy for reference.
- Disconnect mains of the welding semi-automatic machine after finishing
work or before a longer break.
ration of using safety and they may expose users to electric shock.
use changes its features and deterioration of technical data.
- Do not make any own modifications of the Compact 220. It may ca-
user's fault causes loss guarantee rights.
- Any adaptations of this machine are prohibited and they cause not
only loss of the guarantee rights but they may be a cause of deterio-
- Any damage of the Compact 220 caused by improper use or through
- It is prohibited switching the semi-automatic machine on at short
ciruit of the welding cables.
- Acceptable range of ambient temperature is from - 10 to + 40 C.
- Acceptable humidity is up to 90 % at t = 20 C.
- Producer reserves the right to change specifications without pre-
vious notice.
Page 10