CIGWELD MPM 20/600 I-PS Setup guide

DOC No: EDW0007 Date: 16-July-97
Issue No: 2
ENGINE DRIVEN WELDER
GENERATING SET
MPM 20/600 I-PS
(Part Number 636806)

1
GENERAL USE INSTRUCTIONS
Read the instructions carefully; proceed according to the regulations in use in the
country where the machine will operate.
TRANSPORTATION
Y 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.
Y If the machine is mounted on a wheels trolley or trailer, be sure the machine is stable
and secure before use.
CAUTION
Y 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.
Y 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.
Y 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.
Y Note: Do not disconnect battery cables when the engine runs. This could result in
serious damage to the machine.
Y 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:
Y
Y Note: for normal transportation, follow the instructions as specified in the
TRANSPORTATION section.

2
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
Y Do not connect the machine to the commercial electric network.
Y Do not work close to flammable materials or where there is explosive gas or vapours.
Y Do not work in confined or poorly ventilated places.
Y Do not touch the exhaust muffler or adjacent components.
Y Do not carry out service operations while the engine is running.
Y Any service on the electrical circuit must be done when the engine is stopped and only
by qualified technicians.
Y 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).

3
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
4
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)
5

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.
6
ENGINE WARRANTY
AND SPARE PARTS

7
FRONT PANEL DESCRIPTIONS
Arc force regulator
N
Earth clamp connection
Y
Remote control switch
M
Welding socket : positive connection
X
Welding current control
L
Welding socket : negative connection
for CC-WORK
Z
CC/CV mode select
I
Welding socket : negative connection
for CV-WORK
V
Fuel meter
H
Serial number
U
Overspeed lamp
G
ELCB (25A earth fault protection)
T
Oil pressure lamp
F
16A single phase circuit breaker
S
Battery charge lamp
E
400V three phase outlet
R
Water temperature lamp
D
230V single phase outlet
Q
Hourmeter
C
Wire feeder connector 14 pin
P
Single phase voltmeter
B
Basic-Cellulose switch
O
Ignition key
A

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 .
8
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.
9

6.1 CONSTANT CURRENT (CC) MODE
^ Set the CC/CV mode switch to the mode CC position.
^ If using a remote control pendant, plug remote pendant into the 14 pin remote control
socket and set the REMOTE CONTROL switch to the REMOTE position. Set the
REMOTE CONTROL switch to the PANEL position if a remote pendant is not used.
Note: When a remote control pendant is fitted (see 'P' on page 7), the Welding
current/voltage control is switched out of the circuit and remote control pendant
has full control over the welding current.
^ For MMAW (stick) welding connected the Electrode Lead to the positive terminal (see
'X' on page 7) and the work lead to the negative terminal (see 'Z' on page 7).
Note: Stick electrodes are generally connected to the positive terminal but if in doubt
consult the electrode manufactures literature.
^ For GTAW (TIG) welding connected the Electrode Lead to the negative terminal (see
'Z' on page 7) and the work lead to the positive terminal (see 'X' on page 7).
7.1 CONSTANT VOLTAGE (CV) MODE
^ Set the CC/CV mode switch to the mode CV position.
^ Connect wire feeder cable to 14 pin remote control socket.
^ If a remote control pendant is plugged into the remote control socket of the wirefeeder
then set the REMOTE CONTROL switch to the REMOTE position. Set the REMOTE
CONTROL switch to the PANEL position if a remote pendant is not used.
Note: When a remote control pendant is fitted (see 'P' on page 7), the Welding
current/voltage control is switched out of the circuit and remote control pendant
has full control over the welding voltage.
^ For GMAW (MIG) welding connected the Electrode Lead to the positive terminal (see
'Y' on page 7) and the work lead to the negative terminal (see 'V' on page 7).
10

8.1 USE OF ENGINE DRIVEN WELDER AS A
GENERATING SET
^ Start the engine ass described in section 4.1
^ Switch the ELCB lever up to setting I (ON). Switch the single phase 16A CB lever up
to setting I (ON).
^ The single phase voltmeter (see 'I' on page 7) reads approximately 170V when the
engine is at idle speed.
9.1 STOPPING ENGINE
^ Disconnect any load from the auxiliary outlets and the welding terminals of the Engine
Driven Welder.
^ Wait approximately 1 minute then turn the ignition key to the 0position and the motor
will stop.
10.1 ENGINE PROTECTION
^ The DAS Engine Protection Device checks for low oil pressure, no battery charge, over
speed, high water temperature and low fuel level conditions when the Engine Driven
Welder is in operation.
^ When a low oil pressure, no battery charge, over speed, high water temperature or low
fuel level condition occurs the DAS stops the engine and illuminates the corresponding
lamp on the control (expect for the low fuel level condition). When the faulty condition
has been removed the engine can be re-started.
^ Note that if the low oil pressure, no battery charge, over speed, high water temperature
or low fuel level condition is still present when after the engine is re-started then the
DAS Engine Protection Device will stop the engine after approximately one minute has
elapsed.
11.1 WARNING
^ In order to preserve the engine performance CIGWELD strongly recommends that the
maintenance schedule is adhered to as specified in the engine manufacturer "Use and
maintenance" user manual. Poor maintenance could result in a shorter operating life,
decreased performance and loss of engine warranty.
^ DO NOT disconnect the battery from the Engine Driven Welder when the engine is
running as this action will cause the alternator regulator to fail.
11

12
MPM 20/600 I-PS
(Part Number 636806)

13
MPM 20/600 I-PS
(Part Number 636806)

Spare parts list MPM 20/600 I-PS (Part Number 636806)
ProtectionOGS1319131
16A circuit breakerOGS63230
ProtectionOGS1393329
25A earth fault protectionOGS83928
Circuit breaker plateOGS1005727
Front plateOGS1948726
Front and coverOGS1870825
Right plate rectifierOGS1872224
Left plate rectifierOGS1872123
Rectifier assemblyOGS1872022
100Ohm-75W resistorOGS1277621
Resistor supportOGS1872420
Tie rodOGS84619
ShuntOGS1872318
20x20 shock absorberOGS1724517
3 poles terminal boardOGS61416
6 poles terminal boardOGS1036415
InsulatorOGS1170714
Electronic panel GS9603/AOGS1857613
PanelOGS1872612
Flex plateOGS1509211
FanOGS1930910
Shaft with rotorOGS193109
Bearing 100/45/25 2RSOGS9038
Seeger ringOGSO9057
ScrewOGS105246
FanOGS105255
Flange with bearing seatOGS105104
Stator protectionOGS193143
Stator protectionOGS193132
StatorOGS194841
DescriptionOrdering
no.
Item
no.
14

Spare parts list MPM 20/600 I-PS (Part Number 636806)
Grate protectionOGS1913462
Earth clamp plateOGS1751461
Plug for welding outletOGS1477760
Welding outletOGS92359
FrameOGS1913558
Left and coverOGS1660257
Right and coverOGS1660156
CoverOGS1660055
DAS : automatic stop for engine protection
(over speed GS9407)
OGS1743554
DAS : automatic stop for engine protectionOGS1561253
Terminal boardOGS1275852
12V relayOGSO33651
24Vac relayOGS1419750
115Vac relayOGS1437049
1K potentiometerOGS90948
PlateOGS1872847
Potentiometer knobOGS1884446
Grub screwOGS1752145
PinOGS1751944
Oil pressure lampOGS1945843
Overspeed lampOGS1026342
Battery charge lampOGS1026441
Water temperature lampOGS1695940
HourmeterOGS91239
Basic/Cellulosic switch assemblyOGS91038
Socket for remote control and wire feeder 14 polesOGS1822537
Switch assemblyOGS1216336
Fuel meterOGS1168835
F.S. 300V voltmeterOGS32234
230V 15A single phase socketOGS1948233
400V 20A three phase socketOGS1948332
DescriptionOrdering
no.
Item
no.
15

Spare parts list MPM 20/600 I-PS (Part Number 636806)
Battery plateOGS1917093
Negative battery charging clipOGS1424892
Positive battery charging clipOGS1424791
Battery clampOGS1008290
92Ah 12V batteryOGS1057389
Radiator plateOGS1917388
Shock absorberOGS1827587
HookOGS1895586
PlateOGS1895485
Stator bracketOGS1931684
Shock absorberOGS1831483
ReactorOGS1528682
Plate for fuel tankOGS1886581
Rubber wire holderOGS1017480
Plate for gas spring filterOGS1913879
Gas spring filterOGSO90778
WasherOGS1253277
TierodOGS1253176
PinOGS1141075
Fuel drain capOGSO92374
Fuel prefilter 2" gasOGS1662073
Fuel filter cap 2" gasOGS1662172
CoverOGS1832971
Fuel floatOGS1571570
Fuel tankOGS1873269
Plate for capacitorsOGS1576268
Plate for capacitorsOGS1948667
3x80µF capacitorOGS1734766
CoverOGS1919265
PlateOGS1698964
WasherOGS1698863
DescriptionOrdering
no.
Item
no.
16

Spare parts list MPM 20/600 I-PS (Part Number 636806)
(*) Only on request
Air filter supportOGS18965111
Frame locking hookOGS10530110
Shock absorberOGS12230109
Rubber pufferOGS14300108
HandleOGS14916107
Pin (*)
OGS13859106
Instrument front cover (*)
OGS18743105
Pivot shaftOGS16005104
Internal short deflectorOGS18741103
Internal cover deflectorOGS18740102
CanopyOGS18960101
Fuel prefilterOGS16468100
SilencerOGS1913799
PackingOGS1873898
Oil pipe capOGS1722297
Oil drain pipeOGS1811196
Oil drain pumpOGSO87095
Battery coverOGS1913694
DescriptionOrdering
no.
Item
no.
17