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.

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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).

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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
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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)
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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.
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ENGINE WARRANTY
AND SPARE PARTS

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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 .
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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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