CIGWELD 636804 Use Instructions

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ENGINE DRIVEN WELDER

GENERATING SET

MPM 12/400 I-KA

(Part Number 636804)

DOC No: EDW0005 Date: 16-July-97 Issue No: 2

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GENERAL USE INSTRUCTIONS

Read the in structions carefully; proceed according to the regulations in use in t he country where the machine will operate.

TRANSPORTATION

The machine must be fixed securely to t he motor vehicle if it has to be moved to t he place of use. Raise the machine using the lifting eye if the model provides it;

o the rwise , lift it u sing a fo rk lift, ta king ca re t hat t he we ight is w ell bala nced on t he two forks. Keep well clear during these operat ions; furthermore, we suggest not t o 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 mach ine is fitte d with a water c ooled engine fill the radiat or circuit with a solution made up by 50% water and 50% antifreeze liquid in the quantity indicated in

the engine SPECIFICATION section.

Note: T he gen e r a tin g s e t is fur nis h e d w ith a fla t ba tte r y a n d w ithou t a c id . Fill it u s in g sulphuric acid in a 30% - 40% concentrated solution to cover t he elements. During

this operation, we suggest the operat or use prot ective gloves and goggles; accidental skin contact with the sulphuric acid solut ion must be washed up immediat ely 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:

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 st agnate. 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 pro per air recycling.

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

clothes.

7- Fu e l r e fill mu s t not be made while s mok in g or c los e to flame s . This op e ration mu s t

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 operat ing 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 co mpromise 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 contr ols 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 t han 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 pr eserve 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 struct ure 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.

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TECHNICAL SPECIFICATION

POWER PLANT INFORMATION

636804 Part number

MPM 12/400 I-KADescription

WELDING GENERATOR D.C.

400A @ 36VMaximum power 350A @ 34VRated output at 60% duty cycle

30A to 400ARange of continuous control

5 minutesDuty cycle period

70VDC open circuit voltage

FInsulation class

IP 23Mechanical protection

30A to 400A CC mode

18V to 40VCV mode

AUXILIARY GENERATOR

Asynchronous Generator type 12kVA @ 400VThree phase power 10kVA @ 230VSingle phase power

50 HzFrequency

RECOMMENDED MANUAL METAL ARC WELDING ELECTRODE

Maximum Electrode DiameterElectrode Description

6.0mmGeneral purpose & low hydrogen

6.0mmCellulose

6.0mmIron powder

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ENGINE

Kubota D 1105-E Make/Type

3Number of cylinders

1124 cc.Displacement

25 HPDiesel engine output

3000 rpmEngine speed

WaterCooling

36.5 Litres Fuel tank capacity

5.1 LitresOil capacity ElectricStarter

12V - 43 AhBattery

97 dB(A)Acoustic energy emission

89 dBAcoustic pressure @ 1 metre 77 dBAcoustic pressure @ 4 metre

275 gram/kW/hourAverage fuel consumption

15 hours Average operating hours

DIMENSIONS AND WEIGHT

1590mm x 730mm x 920 mmDimensions (Length x Width x Height)

460 KgWeight

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ENGINE WARRANTY

AND SPARE PARTS

1.1 INTRODUCTION

Car efully follow the KUBOTA engine opera tion manua l for s afe opera tion and long service life of this product.

1.2 ENGINE WARRANTY

To secu r e war r a nt y for the engine ensur e tha t the war r a nt y cer t ific a te is fill in and mailed t o the Tutts state branch office (KUBOTAs Australian engine distributor)

The engine is warranted for twelve (12) months from date of purchase or one thousand (1000) hours which ever is sooner . T his wa r r a nt y is limit ed to t he rep la cement or r ep a ir , a t T ut t s wor ks hop of a ny parts proven defective, under normal use and service within the warranty period. For warranty service outside a Tutts workshop, all travelling time and mileage incurred, will of necessity, be charged to the owner of the equipment who ordered the off site warranty repair(s). New engine warr anty does not a pply to maintenance items such as filt ers, hoses, belts, pr eheaters, injection nozzles, packing and seals, etc.

Tutts Branch Network Tutts (Sydney): 2 South St. Rydalmere NS W 2116

Tutts (Perth): 50 Great Eastern Hwy South Guildford WA 6055 Tutts (Brisbane): 39 Suscatand St Rocklea QLD 4106 Tutts (Melbourne): Gwelo St Tottenham VIC 3012

Tutts Dealer Network

Queensland: Andrew's Agricultural Centre Pty Ltd - Goranvale, Cairns Ph: (070) 565222

- Innisfail Ph: (070 616466

- Tully Ph: (070) 681311 Fishabout Pty Ltd - Mackay Ph: (079) 534752 Dore Power Equipment Pty Ltd - Roma Ph: (076) 221883

New South Wales: SJ & ML Foster - Moree Ph: (067) 525 488

Clares Diesel Service Pty Ltd - Coffs Harbour Ph: (066) 525121 Kentan Pty Ltd - Hexham, Newcastle Ph: (049) 648275

Tasmania: Diesel & Marine Pty Ltd - Newtown, Hobart Ph: (03) 62281755 South Australia: Mac Pac Sales & Service Pty Ltd - Wingfield, Adelaide Ph: (08) 82431422

1.3 SPARE PARTS

KUBOTA engine:Contact Tutts (in Australia) 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 KUBOTA Dealer. KUBOTA guarantees an efficient technical support throughout Australia and New Zealand.

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 13.

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FRONT PANEL DESCRIPTIONS

Ignition key

Single phase voltmeter

Hourmeter

Water temperature lamp

Battery charge lamp

Oil pressure lamp

Glow plug lamp

Fuel meter

Throttle switch

CC/CV mode select

Welding current control

Remote control switch

Arc force regulator

Basic / Cellulose switch

Wire feeder connector 14 pin

230V single phase outlet

400V three phase outlet

16A single phase circuit breaker

ELCB (25A earth fault protection)

Serial number

Earth connection

Welding socket : negative connection

for CV-WORK Welding socket : negative connection

for CC-WORK Welding socket : positive connection

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OPERATING INSTRUCTIONS

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 eart h wire to the Eart h connection located on the front of the machine.

2.1 EARTH FAULT PROTECTION

Supply Authorities recommend that protection devices immediately disconn ect all power in the event of an earthing fault. This equipment is fitted with a Eart h Leakage Circuit

Br e a ker ( ELC B ) t h a t inte rr u p ts the a u x ilia ry pow e r c ir c u it w ith in 0 .2 s e c onds w h e n the earth leakage is greater than 30 mA.

If a fa ult o c c ur s in eq u ipme nt c o nn ec t e d t o t he a ux iliar y pow er s upply, 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 eng ine is ru nning . T his w ill re sult in t he ELC B t rip ping re sult ing th e lev er r et ur ning to setting

If t he ELCB trip s rep eat edly while o perat ing au xiliary equ ipment , have t he eq uipment

0 (OFF)

. Reset to setting

I (ON)

tested by a qualified electrical tradesperson.

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4.1 STARTING ENGINE

Che c k t h a t en g ine s fuel tan k h a s be e n fille d with d ie s e l a nd th e su mp h a s be e n fille d w ith lubricating oil as specified in the Engine Manual.

Po s itio n t h e ig nit io n ke y o n t he firs t st e p fo r pr elimina r y hea t ing o f t he g low plu gs , th e glo w plu g lig ht illumin at es . When glo w plu g light t u rns o ff, st ar t th e e ngin e b y mov ing

key completely clockwise.

Aft er st a rt ing th e e ngin e, allo w it t o wa rm u p b y wait ing 10 s min ut e b efo r e lo ad ing t he 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 to I (ON) or 0 (OFF) position.

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.

In standby mode, ie not welding or supplying power to auxiliary o ut le ts , t h e en g in e id le s at approximately 2000 rpm.

When an arc is struck or t he unit is supplying power to auxilia r y outle ts the n the e ng in e s speed increases to appr oximately 3000 rpm. The returns to idle speed approximately 25

seconds after welding has ceased.

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6.1 CONSTANT CURRENT (CC) MODE

Set the CC/CV mode switch to the mode CC position.

If using a remote contro l pendant, plug remote pendant into the 14 pin remote co ntrol 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 'Q' 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 'W' on page 7) and the work lead to the negative terminal (see 'Y' 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 'Y' on page 7) and the work lead to the positive terminal (see 'W' 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 co ntrol pendant is plugged into the remote contr ol 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 'Q' 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 'W' on page 7) and the work lead to the negative terminal (see 'X' on page 7).

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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.

In standby mode, ie not welding or supplying power to auxiliary o ut le ts , t h e en g in e id le s at approximately 2000 rpm.

When an arc is struck or t he unit is supplying power to auxilia r y outle ts the n the e ng in e s speed increases to appr oximately 3000 rpm. The returns to idle speed approximately 25

seconds after the auxiliary equipment is disconnected from the auxiliary outlets.

9.1 STOPPING ENGINE

Dis co nnec t a ny loa d fr om t he aux iliar y out let s a nd t he weld ing t er minals of t he E ng ine Driven Welder.

Wait approximately 1 minute then turn the ignition key to the 0 position and the motor will stop.

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10.1 ENGINE PROTECTION

The DAS Engine Pro tection Device checks for low oil pressure, no battery charge, high water temperature and low fuel level co ndit ion s whe n th e Eng ine D riven Welde r is in

operation.

When a low oil pressure, no battery charge, high water temperature or low fuel level co ndit ion occ urs the DAS sto ps the engin e and illuminat es t he c or res po nding lamp o n

the contro l (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, high water temperature or low fuel level c o nd it ion is s t ill pr es ent w he n aft e r t he e ng ine is r e- st ar t ed t he n t he DA S E ng ine

Protection Device will stop the engine after approximately one minute has elapsed.

11.1 WARNING

In order t o 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.

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MPM 12/400 I-KA

(Part Number 636804)

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MPM 12/400 I-KA

(Part Number 636804)

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