CIGWELD MPM 20/600 I-PS Guida all'installazione

DOC No: EDW0007 Date: 16-July-97

Issue No: 2

ENGINE DRIVEN WELDER

GENERATING SET

MPM 20/600 I-PS

(Part Number 636806)

GENERAL USE INSTRUCTIONS

Read the instructions carefully; proceed according to the regulations in use in the

country where the machine will operate.

TRANSPORTATION

The machine must be fixed securely to the motor vehicle if it has to be moved to the

place of use. Raise the machine using the lifting eye if the model provides it;

otherwise, lift it using a forklift, taking care that the weight is well balanced on the

two forks. Keep well clear during these operations; furthermore, we suggest not to

keep the machine suspended for long.

If the machine is mounted on a wheels trolley or trailer, be sure the machine is stable

and secure before use.

CAUTION

Note: The generating set or the welder is furnished WITHOUT lubricating oil.

Provide the machine with "10 W 40" multi-grade oil indicated for temperatures

from - 20°C to 40° C in the quantity indicated in the engine SPECIFICATION

section.

Note: If the machine is fitted with a water cooled engine fill the radiator circuit with a

solution made up by 50% water and 50% antifreeze liquid in the quantity indicated in

the engine SPECIFICATION section.

Note: The generating set is furnished with a flat battery and without acid. Fill it using

sulphuric acid in a 30% - 40% concentrated solution to cover the elements. During

this operation, we suggest the operator use protective gloves and goggles; accidental

skin contact with the sulphuric acid solution must be washed up immediately with

cold water and, if necessary, a doctor must be consulted.

Note: Do not disconnect battery cables when the engine runs. This could result in

serious damage to the machine.

Note: BEFORE OPERATING THE MACHINE the neutral, or the equivalent

winding point, MUST be connected effectively to earth using an earth stake (without

any switch or other device that may interrupt the electrical connection) from the earth

stud available on the machine, and identified by the symbol:

Note: for normal transportation, follow the instructions as specified in the

TRANSPORTATION section.

RUNNING IN

For the first 50 hours of operation of the machine do not employ more than 70% of the

maximum power indicated in the technical specifications.

STARTING AND WORKING

1- Make the earth connection (see the USE INSTRUCTIONS).

2- If the machine model IS NOT equipped with a earth leakage circuit breaker the

available socket is intended ONLY for connecting the machine to a switchboard

equipped with all protection devices imposed by current law regulations.

3- Check the state and efficiency of the cables.

4- Make sure that all the switches and electric connections are in the right position for

starting (see USE INSTRUCTIONS and CONTROL PANEL DESCRIPTIONS).

5- Use the machine in well ventilated places, taking care that the exhaust gas and the

welding fumes produced (where welders are used) do not stagnate. Keep the machine

away from walls or other obstacles in order to avoid air or gas recycling. If the

machine is employed in closed places, use forced ventilation in order to ensure proper

air recycling.

6- While welding, eyes and body must be protected by gloves, mask and appropriate

clothes.

7- Fuel refill must not be made while smoking or close to flames. This operation must

be done when the engine is switched off.

8- Do not over fill the tank and clean up any spillage.

9- Check daily for loss of fuel or lubricating oil.

10-For machines provided with a liftable canopy engage the canopy securing brackets

where fitted.

WARNING

Do not connect the machine to the commercial electric network.

Do not work close to flammable materials or where there is explosive gas or vapours.

Do not work in confined or poorly ventilated places.

Do not touch the exhaust muffler or adjacent components.

Do not carry out service operations while the engine is running.

Any service on the electrical circuit must be done when the engine is stopped and only

by qualified technicians.

Keep clear of moving parts of the engine while it is operating and do not approach the

machine with loose fitting clothing.

SERVICE AND CLEANING

We suggest frequent cleaning of the machine since the presence of dirt can compromise

efficiency.

The frequency of this operation depends on the environment in which the machine is

used. We advise to pay special care to the service of::

OIL LEVEL, OIL FILTER, AIR FILTER, FUEL FILTER, COOLING LIQUID

LEVEL, RADIATOR, VENTILATION DUCTS AND INTAKES, BATTERY

ENGINE USE AND SERVICE manual and the SPECIFICATION section to know

how and when it is useful to do it. The extraordinary service operations not mentioned

herein require the aid of specialised technicians (see the Engine Dealers list).

For service intervals consult the ENGINE USE AND SERVICE manual and the

SPECIFICATION.

ADJUSTMENTS AND REGULATIONS

All necessary controls are located on the main control panel and are properly explained

in the section FRONT PANEL DESCRIPTION.

We advise the operator against tampering with the engine or the internal electrical

components.

Note: Modification of the normal parameters can compromise the reliability of the

machine.

PROLONGED STANDING PERIODS

If the machine has to be stopped for a long period (more than one year), we suggest to

leave the motor oil and the fuel in and the water in the radiator in order to avoid

oxidising effects.

When the machine is to be used, the liquids must be replaced, the battery must be

charged; the belts, pipes and rubber hoses must be checked and a visual inspection of the

electrical connections must be done.

SCRAPPING

In order to preserve the environment, it is advised to dispose of the oil, fuel and battery

in an approved manner. For the complete range of materials, see the list below:

FERROUS and NON-FERROUS MATERIALS:

steel, cast iron, aluminium, copper, brass are used in the structure of engine,

alternator, transformers, etc.

PLASTIC MATERIALS:

rubber, bakalite, epovit, lexan are used for the instruments, engine pipes,

junction boxes and connectors, fuel tank, fuel cap, wheels, anti-vibration

dampers, condenser housings, fans, belts, filters and hoses.

ELECTRONIC MATERIALS:

various components, diodes, resistors, electronic panels.

VARIOUS MATERIALS:

rock wool, sound proofing materials.

LIQUIDS:

fuel, gasoline, cooling liquids, battery acid.

POWER PLANT INFORMATION

MPM 20/600 I-PSDescription

636806Part number

WELDING GENERATOR D.C.

18V to 40VCV mode

30A to 600ACC mode

IP 23Mechanical protection

FInsulation class

70VDC open circuit voltage

30A to 600ARange of continuous control

5 minutesDuty cycle period

500A @ 40VRated output at 100% duty cycle

600A @ 40VRated output at 60% duty cycle

AUXILIARY GENERATOR

50 HzFrequency

12kVA @ 230VSingle phase power

20kVA @ 400VThree phase power

AsynchronousGenerator type

RECOMMENDED MANUAL METAL ARC WELDING ELECTRODE

10.0mmIron powder

10.0mmCellulose

10.0mmGeneral purpose & low hydrogen

Maximum Electrode DiameterElectrode Description

TECHNICAL SPECIFICATION

ENGINE

220 gram/kW/hourAverage fuel consumption

78 dBAcoustic pressure @ 4 metre

90 dBAcoustic pressure @ 1 metre

98 dB(A)Acoustic energy emission

12V - 92 AhBattery

ElectricStarter

9.1 LitresOil capacity

60 LitresFuel tank capacity

WaterCooling

1500 rpmEngine speed

64.4 HPDiesel engine output

3861 cc.Displacement

4Number of cylinders

Perkins 4.236Make/Type

DIMENSIONS AND WEIGHT

1000 KgWeight

1950mm x 800mm x 1100 mmDimensions (Length x Width x Height)

New engine warranty does not apply to maintenance items such as filters, hoses, belts, preheaters,

injection nozzles, packing and seals, etc.

Defects

This warranty covers Engine REPAIRS to correct any failure occurring during the WARRANTY

PERIOD due to defect in the workmanship or material thereof.

Warranty Period

The engine is warranted for twelve (12) months from date of delivery to the first user providing the

Engine is sold to the first user within 12 months from the date of dispatch by the Company. Engines

sold after 12 months from the date of dispatch by the Company must have had the self-life warranty

reinstated, registered and be current prior to retail sale or the engine is void of warranty.

Repairs

To obtain warranty repairs, you must request the needed repairs within the WARRANTY PERIOD

from an authorised Perkins service outlet. Only new genuine parts or re-manufactured parts or

components supplied or approved by Perkins will be used. Perkins may, at it's discretion, replace

rather than repair components. A reasonable time must be allowed to perform the warranty repair

after taking the engine to the authorised service outlet. Repairs due to accident, misuse,

misapplication, storage damage, negligence or modification exceeding Perkins specifications are not

covered by this warranty.

Maintenance

Perkins is not responsible for the cost of maintenance or repairs due to lack of performance of normal

maintenance service or the failure to use fuel, oil, lubricants and coolant meeting Perkins

recommended specifications. Proof of proper maintenance and use of proper fuel, oil, lubricants and

coolant are the responsibility of the owner. See "Perkins Operator's Handbook" for full details.

To secure warranty for the engine you must notify your local authorised Perkins service outlet.

1.2 ENGINE WARRANTY

Carefully follow the PERKINS engine operation manual for safe operation and long service life of

this product.

1.1 INTRODUCTION

1.3 SPARE PARTS

PERKINS engine: Contact authorised Perkins Dealer for spare parts and service assistance. Specify

the engine model number, serial number, name of part (with code number), Engine

Driven Welder model name (with code number) and manufacturers name when you

contact your Perkins Dealer.

Generator and equipment: Contact your local CIGWELD Distributor for spare parts. Specify the

Engine Driven Welders model number, serial number and name of part

(with code number) when ordering spare parts. Refer to the Spare Parts

List from page 12.

ENGINE WARRANTY

AND SPARE PARTS

FRONT PANEL DESCRIPTIONS

Arc force regulator

Earth clamp connection

Remote control switch

Welding socket : positive connection

Welding current control

Welding socket : negative connection

for CC-WORK

CC/CV mode select

Welding socket : negative connection

for CV-WORK

Fuel meter

Serial number

Overspeed lamp

ELCB (25A earth fault protection)

Oil pressure lamp

16A single phase circuit breaker

Battery charge lamp

400V three phase outlet

Water temperature lamp

230V single phase outlet

Hourmeter

Wire feeder connector 14 pin

Single phase voltmeter

Basic-Cellulose switch

Ignition key

1.1 EQUIPMENT GROUNDING CONNECTION

This machine has auxiliary power capability and grounding of the frame and case is

recommended. Refer to your local Supply Authority or Australian Standard AS3000 for

detailed earthing instructions. Connect the earth wire to the Earth connection located

on the front of the machine.

2.1 EARTH FAULT PROTECTION

Supply Authorities recommend that protection devices immediately disconnect all power

in the event of an earthing fault. This equipment is fitted with a Earth Leakage Circuit

Breaker (ELCB) that interrupts the auxiliary power circuit within 0.2 seconds when the

earth leakage is greater than 30 mA.

If a fault occurs in equipment connected to the auxiliary power supply, the outer casing

may become live and result in serious injury. The Engine Driven Welder must be

properly earthed. Refer to your local Supply Authority or Australian Standard AS3000

for detailed earthing instructions. The user is responsible for connecting this Engine

Driven Welder to earth.

3.1 USE AND TESTING OF EARTH FAULT PROTECTION

Switch the ELCB lever up to setting I (ON). Test by pressing the test button while the

engine is running. This will result in the ELCB tripping resulting the lever returning to

setting 0 (OFF). Reset to setting I (ON).

If the ELCB trips repeatedly while operating auxiliary equipment, have the equipment

tested by a qualified electrical tradesperson .

OPERATING INSTRUCTIONS

4.1 STARTING ENGINE

Check that engines fuel tank has been filled with diesel and the sump has been filled with

lubricating oil as specified in the Engine Manual.

Position the ignition key on the first step for preliminary heating then start the engine by

moving key completely clockwise.

After starting the engine, allow it to warm up by waiting 5 minutes before loading the

Engine Driven Welder.

Do not move the throttle control lever.

5.1 USE OF ENGINE DRIVEN WELDER AS A WELDER

Insert welding cable plugs into relevant sockets.

Set the current/voltage control knob on the front panel to the desired value on the

Engine Driven Welder. Take care that the REMOTE CONTROL switch is in 0 (OFF)

position.

Set the Arc Force control.

Remote current control can be achieved by using a remote control device.

When operating with remote control switch the remote switch control to position I

(ON) and connect the cable of the remote control unit to the 14 pin remote control

socket.

Connected the Electrode Lead to the positive terminal and the work lead to the

negative terminal.

Note: Stick electrodes are generally connected to the positive terminal but if in doubt

consult the electrode manufactures literature.

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