Comparc BRONCO 255K XD, Owner'S Manual

Page 1: ...ENERATOR PROCESS STICK SMAW DESCRIPTION CC CV TIG GTAW MIG GMAW WELDINGGENERATORTYPE AC DC CONSTANTCURRENT CONSTANTVOLTAGE CC CV PM1323 REV 0 E 21 01 2021 304 855 T M OWNER S MANUAL GIVETHISMANUALTOTH...

Page 2: ...trol 9 4 6 Engine Control 9 4 7 Burnbank Optional 9 4 8 Mig welding outputs and settings controls 10 4 9 Optional controls and indicators 11 SECTION 5 AUXILIARY POWER 12 5 1 Receptacles 12 5 2 Wiring...

Page 3: ...ged parts at once 12 Wear a safety harness to prevent falling if working above floor level 13 Keep all panels and cover securely in place ARC RAYS can burn eyes and skin NOISE can damage hearing Arc r...

Page 4: ...ng or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental stating during servicing disconnect negative battery...

Page 5: ...riod follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE...

Page 6: ...y signal words SECTION 1 SAFETY SIGNALS AND SYMBOLS WARNING CAUTION IMPORTANT Statements identify special instructions necessary for the most efficient operation of thisequipment WARNING statements id...

Page 7: ...PERES 240 V The ac power curve shows the auxiliary power in amperes available at the 120 and 240 volts receptacles L H IDLE 2200RPM The fuel consumption curves shows Typical Fuel use under weld or pow...

Page 8: ...CC DC CV DC 175 300 20 90 30 40 50 60 70 80 100 10 Duty cycle is percentage of 10 minutes that unit can work at rated load without overheating This unit can work at 100 of Duty cycle Allowing a const...

Page 9: ...1 SELECTING A LOCATION MOVING WELDING SOURCE READ SAFETY BLOCKS at beginning of manual before proceeding 1 Keep free space 457mm 18 around the unit for a good air flow 2 Lifting eye Use only for lift...

Page 10: ...tick Check oil level after fueling with unit on level surface If oil level is not up to full mark on dipstick add oil see engine manual for more specifications 3 Oil fill tube If fuel do not close to...

Page 11: ...0 2 0 4 2 1 1 0 2 0 3 0 3 1 1 0 2 0 3 0 4 0 2 1 0 2 0 3 0 4 0 2 2 0 1 2 0 3 0 4 0 2 2 0 2 3 0 1 0 3 0 4 0 2 2 0 2 3 0 2 3 0 1 0 3 0 4 0 2 2 0 2 3 0 2 4 0 Weld cable size AWG is based on either a 4 vol...

Page 12: ...late total cable length in weld circuit b Determine maximum welding current and duty cycle c Use table 3 1 to select proper cable size 2 Terminal lug Use lugs of proper amperage capacity and hole size...

Page 13: ...w range in coarse range selector CD current VC mode See sec 4 3 CAUTION ARCING can damage switch Do not change AC DC polarity switch position while welding Arcing inside switch can damage contact caus...

Page 14: ...not Use Place the Switch in the OFF position to preven discharging the battery 4 CHOKE Choke control is provided for varying the fuel air mixture to the engine Set ignition switch in Start position P...

Page 15: ...CIRCUIT BREAKER CB6 Protects to 24 Vac winding agains overloads on receptacle RC4 4 RECEPTACLE RMT 14 RC4 Insert the conector of the wire feeder and tighten firmly this reeceptacle supply 24 Vac to w...

Page 16: ...uipment Install Prepare wire feeder Use The Safety Equiment Set Controls Open Gas Valve Start the Engine Turn On Auxiliary Equipment Turn On Wire Feeder Begin to Weld Install Connect the Equipment Ins...

Page 17: ...e button to reset CB1 or CB2 6 circuit Reset CB3 AND CB4 CB3 and CB4 protect RC1 RC2 and RC3 The combined power of all receptacles is limited to 10 0kVA kW nominal generator Example If 20 A is draw fr...

Page 18: ...rs Strip conductors enough to make good contact with plug terminals Make plug connections and reisntall outer shell and cord grip Tighten assembly screws onto shell Do not cover tighten 9 Auxiliary Po...

Page 19: ...tighten Battery Connections Service Air Cleaner 100 HOURS Replace Fuel Filter Engine Manual Check Valve Clearance Repair Or Replace Damaged Cables Check Spark Plugs 1000 HOURS Blow out Or Vacuum Insi...

Page 20: ...rmance at 0 F 18 C 430 Amps Engine RPM no load Weld power 3700 Idle 2200 Changeeachyear Spark plugGap 0 030 in 0 8 mm Spark plug STD Part number 1213202 S Check daily oil level Recomended oil SAE 30 C...

Page 21: ...ely with air Impregnate the foam rubber element with SAE 30 oil and wring the oil excess 2 Filter Replace if filter is damage or dirty 6 4 OIL CHANGE OIL FILTER AND FUEL FILTER Stop engine 1 Oil drane...

Page 22: ...If the battery voltage is less than 12 4 volts recharge the battery as instructed by the battery charger To replace the battery do the following Disconnect the battery cables negative cable first 8 Ba...

Page 23: ...o the solenoid valve and adjust the following Slide the solenoid valve to front for increasing the speed or to back for decreasing the speed up to adjust the engine speed to 2200 rpm and tight the scr...

Page 24: ...NING READ SAFETY BLOCKS at beginning of manual before proceeding 1 Fuse F6 The fuse F6 protect the engine electrical sistem from overload if F6 is open the battery no charge 6 8 ENGINE ELECTRIC SYSTEM...

Page 25: ...TIC WELD OUTPUT HIGH OR LOW WELD OUTPUT Clean tighten all weld connections on welder generator Contact your authorized sevice center for clean slip rings and install new brushes if necessary TABLE 6 1...

Page 26: ...ERATION BATTERY DISCHARGES BETWEEN USES Tune engine according to engine manual Check and adjust engine speed Check continuity of speed control switch SW7 and replace if necessary UNSTABLE OR SLUGGISH...

Page 27: ...E MEV SPEED MODULE CT 1 CURRENT TRANSFORMER RC4 RECEPTACLE 14SKT F6 INCLUDED IN THE HARNESS AC 1 8 16 16 19 17 7 P DC Z S 1 F 3 6 4 WORK V C C2 R2 SR 1 33 A 33 A CB3 CB6 CB8 CB7 RC4 CB1 CB2 33 33 B W...

Page 28: ...rement in watts 120 V x 4 5 A 540 W Therefor the individual load applied by the drill is 540Watts EXAMPLE 2 If a flood lamp is rated at 200W the individual load applied by the lamp is 200W if three 20...

Page 29: ...P 1 HP 1 1 2 HP 2 HP 3 HP 5 HP 2020 3075 4500 6100 8200 10550 15900 23300 720 975 1400 1600 2200 2850 3900 6800 Capacitor Start Induction Run 1 1 2 HP 5 HP 7 1 2 HP 10 HP 8100 23300 35000 46700 2000 6...

Page 30: ...A FIG 7 3 POWER REQUIRED TO START MOTOR FIG 7 4 STARTING AMPERAGE CALCULATION G KVA HP 6 3 H 7 1 J 8 0 K 9 0 L 10 0 M 11 2 N 12 5 P 14 0 1 MOTOR RATING LABEL 2 MOTOR START CODE Determine power requir...

Page 31: ...35 Panel front Panel side Right Panel cover Panel side Left Gasket baffle assembly Baffle support Frame lifting Baffle lower Reactor Stabilizer Mounting support Fuel tank assembly Fuel sender Frame fr...

Page 32: ...PM1323 FIG 9 1 GENERAL ASSEMBLIY 1 2 5 4 8 9 14 15 16 13 12 10 11 7 6 24 23 22 21 20 18 19 25 27 28 17 26 30 30 29 31 3 32 33 34 35 27...

Page 33: ...2 3 4 5 6 7 8 9 10 engine adapter Fan aluminium Bearing secure Cover front Bearing Brushes assembly Brushes Brushes holder Brushes cover Brushes support stator Rotor Fan rotor I D ITEM PA1003 PV0240 M...

Page 34: ...03985 MM04391 PC1508 PT1395 PP4303 PP4304 MP07978 PM0330 MP08417 MC10319 MC10192 MR02583 MR10523 Rheostat 100 w 10 Nameplate upper Panel front Switch range Switch polarity Receptacle duplex 120 Vac 20...

Page 35: ...PM1323 6 7 21 8 17 15 16 14 18 12 1 2 3 3 3 4 5 19 20 10 9 11 16 13 30...

Page 36: ...ate Rectifier Positive Negativeplate Rectifier support Filter consisting of Resistor 1 K Capacitor 47 F 200V Diode 6A 600 V Is included in the harness Rectifier 30 A 600 V Holder SB 500 6 Speed contro...

Page 37: ...motor drive system drive roll excluded and any other part the requires the removal of sheet metal 2 1 Year Parts Labour CG1 Dart Track Cutter excluding tracks Welding positioners turning rollers Auto...

Page 38: ...NOTES...

Page 39: ...SERVICE CENTER FAX MAP CANADA LTD 325 Healey Road Unit 1 Bolton ON L7E 5C1 Canada Phone 905 951 2788 Toll Free 800 757 4445 Fax 905 951 6256...