CT 230 YSX CC/CV
Contents
1. atte 1 SELETTORE CORRENTE 1 RANGE b n ri y 190 130 Y T Sa V Y Y Pasi Ya 2X x I 127 ps 1 W Mal TEAD 1 I la py 2274 ila IP 125 7 l VM 2 Tes 3 lt 7 4444 16 I N 27 lt ey y 7 5 7 s d 5 7 9 8 4 2 11 TC 2 TC 2 50 11A TC 2 50 Descr 209519904 CONNETTORE COMPLETO DI CAVI CONNECTOR WITH CABLES 2 vers 930609904 CONNETTORE CON CAVI CONNECTORS WITH CABLES TC2 50 vers 107509702 MANOPOLA REG CORRENTE SALDAT KNOB WELDING CURRENT REGULAT 107509700 POTENZIOMETRO WELDING CURRENT REGULATOR Fino a Up to REV 10 99 Del 129 06 04 09 07 836709715 POTENZIOMETRO WELDING CURRENT REGULATOR Da From REV 07 07 Del 129 06 04 09 07 107509900 SCATOLA CASE BOTTOM HALF 209519901 COPERCHIO CD COVER 209510018 TC2 COMANDO DISTANZA STD TC2 STD REMOTE CONTROL 930600018 102 50 COMANDO DISTANZA STD TC2 50 STD REMOTE CONTROL 18 10 99 KD2. 4 E AW 7 A ee cS e Y e 1 1 a co e CN gt LU Ci Ricambi MOSA 68 Spare parts MOSA 1 20 1 7 13 qm 15 16 Tavola ricambi MOSA Spare parts table 230 5 CC CV omosa _ 2 12 08 CE Table pi ces de rechange Pos Cod Desa 1 372802071 GUARNIZIONE X COLL SCARICO 2 HP0211242 CORNICE FISS PROFILATO GOMMA 3 3 2802135 DEFLETTORE SCARICO ARIA MOTORE 4 256602228 FILTRO GASOLIO 5 3 2801082 TRAVERSA PROTEZIONE SIL SCAR 6 HP0212070 TUBO SCARICO 7 209502071 GUARNIZIONE SILENZIAT SCARICO 9 372955107 SENSORE DI HALL 300A 9 372801105 STAFFA FISSAGGIO MOLLA A GAS 10 3 2808218 PARATIA INFERIORE ALTERNATORE 11 102302280 GUARNIZIONE L MT 1 qm 12 356721100 ROLL BAR 13 105112270 GUARNIZIONE L MT 1 qm 14 0211046 PARATIA PER CAMERA ASPIRAZIONE 15 372859150 BATTERIA 16 259109154 STAFFA FISSAGGIO BATTERIA 17 000037295 725 ASSIEME RETE R C VRD 20 794004100 REATTORE DI LIVELLO 21 372808121 COPERTURA SCATOLA ELETTRICA Pos Cod Desa 1 372802071 GASKET FOR EXHAUST MANIFOLD 2 HP0211242 RUBBER FIXING FRAME 3 372802135 DEFLECTOR FOR ENGINE AIR EXHAUST 4 256602228 FUEL PRE FILTER 5 372801092 CROSS PROTECTION EXHAUST SILENCER 6 HP0212070 EXHAUST PIPE 7 209502071 GASKET FOR EXHAUST 9 372955107 HALL SENSOR 9 372801105 FIXING BRACKET X SPRING 10 3 2808218 ALTERNATOR UNDERWALL 11 10
3. MOSA CONTROLS LEGENDE REV 1 10 07 CF Hydraulic oil level light Welding socket Welding socket Earth terminal A C socket Accelerator lever Feed pump 48V D C socket Engine air filter Oil level dipstick Engine oil reservoir cap Hydraulic oil reservoir cap Water filling cap Fuel prefilter Fuel tank cap Muffler Stop control Engine protection cover Engine cooling alternator fan belt Oil drain tap Hydraulic oil drain tap Water drain tap Exhaust tap for tank fuel Button Start button Booster socket 12V Booster socket 24V Battery charge fuse Space for remote control Remote control Space for 5 Space for PAC Fuel pump Electric start socket Reset button PTO HI Quick coupling m PTO HI Quick coupling f PTO HI Hydraulic oil filter Battery charger thermal switch Engine thermal switch Aux current thermal switch Supply thermal switch wire feeder 42V Pre heater spark plug thermal switch Supply thermal switch oil water heather Electropump thermal switch No load voltage control Choke control Auxiliary welding current control Cellulosic electrodes control Voltmeter relay Warning lights Selecting knob Load commut push button starting push button Operating mode selector Power on warning light Display Wire connection unit Selector Setting confirmation Fuel valve Oil syringe Insulation monitoring Button indicating light 30 11 PTO HI Engine control un
4. CD Tavola ricambi Spare parts table e SI e 65 e gt e LO gt a oc MOSA Tavola ricambi LI Es A 68 Spare parts table _ REv 0 04 05 Table pi ces de rechange Descr Note 1 372802139 FASCIA FISSAGGIO SERBATOIO 2 209702242 RACCORDO 3 372822020 SERBATOIO CARBURANTE 4 356722050 SILENZIATORE SCARICO 5 372801050 BASAMENTO 6 372809875 INDICATORE RISERVA CARBURANTE 7 272822228 FILTRO PER SERBATOIO 8 372802026 TAPPO SERBATOIO CARBURANTE 9 372821031 TUBO MANDATA CARBURANTE Pos Rev Cod Descr Note 1 372802139 FIXING TANK BAND 2 209702242 PIPE FITTING FOR TANK 3 372822020 FUEL TANK 4 356722050 EXHAUST MUFFLER 5 372801050 BASE 6 372809875 FUEL LEVEL FLOAT 7 272822228 8 372802026 FUEL TANK 9 372821031 FUEL OUTLET TANK CT 230 SX 06 04 05 37285 1 2 372800130 1 0 10 01 mms m s sull 102042490 RUOTA WHEEL 372801234 MANIGLIA DX DI STAZIONAMENTO STANDING KNOB 372801235 MANIGLIA SX DI STAZIONAMENTO STANDING KNOB LEFT 372801160 ASSALE AXLE 6075020 COPIGLIA PIN SPLIT 29 10 01 KA MOSA CD 68 REV 1 07 07 TC 2 TC2 50 209510018 930600000 70 N Vs 180 NN 1 ON Y 1 V Z 100
5. Sal 10 10 02 1 4 indication is shown clear readable indeleble way on sticker MOSA Technical data 230 5 CC CV MOSA REV 0 12 08 The CT 230 engine driven welder ia a unit which ensures the function as a a current source for arc welding b a current source for the auxiliary power generation It is meant for industrial and professional use powered by an endothermic engine it is composed of various main parts such as engine alternator electric and electronic controls the fairing or a protective structure The assembling is made on a steel structure on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise Technical data 230 YSX CC CV GENERATOR Three phase power 6 kVA 400 8 7 A Single phase power Single phase power 230 V 21 7 2 5 KVA 110 V 22 7 Frequency 50 Hz ALTERNATOR self excited self regulated brushless Type three phase asynchronous Insulating class H ENGINE Mark Model Yanmar L 100N Type 4 Stroke Cylinders Displacement 1 435 cm Net power 6 5 kW 8 8 HP Speed 3000 rpm Fuel Fuel consumption Diesel 254 g kWh Cooling system Air Engine oil capacity 1 6 Starter Electric GENERAL SPECIFICATIONS Tank capacity 23 Running time at duty cycle 60 20h Protection IP 23 Dimensions max Lxwxh mm 1050x650x920 Weight 247 K
6. 230 5 CC CV 372999003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG 17 12 08 3 299M00 preparato UPT approvato da DITE 01 MOS GS DESCRIPTION THE MACHINE 230 YSX CC CV MOSA REV 0 12 08 Main characteristics of the unit e Multi process welder SMAW Shielder Metal Arc Welding Stick GMAW Gas Metal Arc Welding MIG Control of current with CHOPPER technology at high frequency Check the maximum engine power Maximum welding current 210A 20V Arc force for cellulosic electrodes 6 kVA of power in three phase generation 400 V 50 Hz Schuko version 5 kVA of power in single phase generation 230 V 50 Hz Yanmar Diesel engine L 100 N more silenced Tank of 23l with autonomy of 20 h Noise level at 7 67dBA Dimensions weight 1050x650x920 247 Kg BATTERY FILTER CONNECTOR FOR REMOTE CONTROL The unit is composed of a structured base which includes a tank an engine alternator unit fixed on the base by 3 elastic dampers a roll bar with hook for an easy and sure lifting a chest hinged to the base for a quick access to the engine to the air filter and to the battery The set is completed by a frontal panel where there is the possibility to start the engine adjust welding parameters and obtain full AUX power m CA GB Quality system MOSA _ 12 05 00 CF THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE and its partner
7. MOSA _ REv 0 12 08 CE Table pi ces de rechange Pos Rex Cod Desa 1 1302500 SEGNALATORE RETT 12V DC ROSSO WARNING LIGHT 2 352007109 PROTEZIONE TERMICA THERMOPROTECTION 3 107302460 STARTER A CHIAVE STARTER KEY 4 105511810 CONTAORE 230V 50Hz IP65 HOURMETER 230V 50Hz IP65 5 232027130 CAPPUCCIO PROTEZIONE 0 6 105277325 INTERRUTTORE MAGNETOTERMICO MAGNETO SWITCH T 220237105 Vedi 256007105 See Part n 256007105 8 232027036 GUIDA FIXING GUIDE 9 103011310 VOLTMETRO FONDO SCALA 300V VOLTMETER 300V 10 105111530 PRESA 32A 110V 2 POLI T SOCKET 32A 110V 2 POLES N 11 307047250 PRESA CEE 110V 16A 2 POLI T EEC SOCKET 110V 16A 2 POLES N 12 307017240 PRESA 220V 16A SOCKET 16A 220V 2P T 13 3 2959800 SCHEDA UNITA CONTROLLO SALD WAC WELDING CONTROL PCB 14 3 2959628 GUARNIZIONE X SCHEDA SALDATURA GASKET FOR WELDING PCB 15 3 2959701 POTENZ LINEARE A FILO POTENTIOMETER 16 372959702 MANOPOLA CON INDICE WITH INDEX 17 765009910 CONNETTORE CONNECTOR 18 765009911 CAPPUCCIO X CONNETTORE CONNECTOR CAP 19 222440543 KIT POTENZIOMETRO MANOPOLA POTENTIOM KIT KNOB 20 372957169 FRONTALE PER SCHEDA SALDATURA FRONT PANEL FOR WELDING PCB 21 382009962 CAPPUCCIO ISOLANTE CAP 22 282009902 DEVIATORE UNIPOLARE SWITCH 25 305159880 BOX CONDENSATORI CAPACITOR BOX 3X75 26 307017037 STAFFA BRACKET 27 209719850 SCHEDA EV ES PCB EV ES 29 218017226 MORSETTIERA TERMINAL BOAR
8. MOVES OF THE MACHINE At any move check that the engine is off that there are no connections with cables which impede the moves PLACE OF THE MACHINE ATTENTION For a safer use from the operator DO NOT fit the machine in locations with high risk of flood Please do not use the machine in weather conditions which are beyond IP protection shown both in the data plate and on page named technical data in this same manual 26 11 99 M2 6GB Installazione Luftzirkulation CA Installation Instalaci n CT 230 SX OMOSA REV 1 12 07 Installation 00 CT 230 YSX CC CV M1 4 L b m1 4 A DU 06 04 05 37285 CD LISA unpacking GE MS TS MOSA 1 1 02 04 Ux Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conforms to local rules and regula tions When receiving the goods make sure that the uct has not suffered damage during the transport that there has not been rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or ab sence of parts envelopes manuals etc we ad vise you to inform immediately our Technical Ser vice For eliminating the packing materials the User must keep to the norms in force in his country bor rb 22111 1 Take the machine
9. tear pages and keep it in places protected from dampness and heat You must take into account that some figures contained in it want only to identify the described parts and therefore might not correspond to the machine in your possession INFORMATION OF GENERAL TYPE In the envelope given together with the machine and or set you will find the manual for Use Maintenance and Spare Parts the manual for use of the engine and the tools if included in the equipment the guarantee in the countries where itis prescribed by law Our products have been designed for the use of generation for welding electric and hydraulic system ANY OTHER DIFFERENT USE NOT INCLUDED IN THE ONE INDICATED relieves MOSA from the risks which could happen or anyway from that which was agreed when selling the machine MOSA excludes any responsibility for damages to the machine to the things or to persons in this case Our products are made in conformity with the safety norms in force for which it is advisable to use all these devices or information so that the use does not bring damage to persons or things While working it is advisable to keep to the personal safety norms in force in the countries to which the product is destined clothing work tools etc Do not modify for any motive parts of the machine fastenings holes electric or mechanical devices others if not duly authorized in writing by MOSA the responsibility coming from any po
10. A2 Remote control welding regulator B2 E P 2 engine protection C2 Fuel level gauge D2 Ammeter E2 Frequency meter F2 Battery charge trasformer G2 Battery charge PCB H2 Voltage selector switch 12 48V a c socket L2 Thermal relay M2 Contactor N2 G F l and circuit breaker 02 42V EEC socket P2 G F l resistor Q2 T E P engine protection R2 Solenoid control PCBT 92 Oil level transmitter T2 Engine stop push button T C 1 U2 Engine start push buttonT C 1 V2 24V c a socket Z2 Thermal magnetic circuit breaker W2 S C R protection unit X2 Remote control socket Y2 Remote control plug X5 Y5 Insulation moitoring E A S connector E A S PCB Booster socket Open circuit voltage switch Stop push button Ignition coil Spark plug Range switch shut down button Battery charge diode Relay Resistor Sparkler reactor Output power unit Electric siren E P 4 engine protection Engine control PCB R P M electronic regulator PTO HI control PCB PTO HI 20 l min push button HI 30 l min push button PTO HI reset push button PTO HI 20 l min indicator PTO HI 30 l min indicator PTO HI reset indicator PTO HI 20 l min solenoid valve PTO HI 30 min solenoid valve Hydraulic oil pressure switch Hycraulic oil level gauge Preheating glow plugs Preheating gearbox Preheating indicator R C filter Heater with therm
11. Set up for operation Engine diesel 1 1 09 05 CF MOSA BATTERY WITHOUT MAINTENANCE Connect the cable positive to the pole positive of the battery after having taken away the protection by properly tightening the clamp Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY SA LUBRICANT RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products Agip Please refer to the motor operating manual for the recommended viscosity REFUELLING AND CONTROL Carry out refuelling and controls with motor at level position 1 Remove the oil fill tap 24 2 Pour oil and replace the tap 3 Check the oil level using the dipstick 23 the level must be comprised between the minimum and maximum indicators ATTENTION It is dangerous to fill the motor with too much oil as its combustion can provoke a sudden increase in rotation speed Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered air to the inside of the motor DRY AIR FILTER TS GE Air cooled systems OIL BATH AIR FILTER Fill the air filter using the same engine oil up to t
12. TCBs pressing the central pole or upwards the lever of the CBs When reset connect the loads again In case the protection should act furtherly check the connections the wires or others and if necessary call the Assistance Service PRESS TO RESET NOTE Avold to hold the central pole of the TCBs pressed for a long time Otherwise in case of trouble it will not click damaging the generator GROUND FAULT INTERRUPTER Turn on the GFI safety switch D by pushing it upwards The GFI is a safety device which protects the circuit in the event of a malfunction In this case the switch disconnects the three and single phase circuit when in some part of the electric connections a current leakage of more than 30 mA occurs 17 12 08 37299 GB CD LISA G accessory USE MOSA 11 06 05 Y a The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector To regulate the current from the TC2 TC2 50 move the switch 7 located above the multipole connector 8 to ON position Position welding current adjusting T knob at the necessary current value for the diameter and type of electrode See page M51 REMOTE CONTROL TC2 TC2 50 PUSH AND SCREW TIGHT 09 11 99 M38GB ENGINE PROTECTION ES EV ENGINE PROTECTION ES EV The devices ES or EV ensure the protection of the engine in case o
13. cust off operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place i 69 O1 30 03 00 M45GB Dimensioni MOSA GB Dimensions Dimensiones mosa Rrev o 0405 Dimensions 0 864 SLENGE ula 58 f N p V 14172 fori 4 n 2 fori 701 128 1095 1410 230 5 230 5 CC CV 06 04 05 37285 O SA RECOMMENDED ELECTRODES in accordance with A W S Standard MOSA 10 10 03 The information here below to be intended only as indicative since the above norm is much larger For further details please see the specific norms and or the manufacturers of the product to be used in the welding process RUTILE ELECTRODES E 6013 Easily removable fluid slag suitable foe welding in all position Rutile electrodes weld d c with both polarities electrode holder at and in a c Suitable for soft steels R 38 45 kg mm Also for soft steels of lower quality BASIC ELECTRODES 7015 Basic electrrodes wels onlu in d c with inverse polarity on the electrode holder there are also types for a c Suitable for impure carbon steels Weld in all position HIGH YIELD BASIC ELECTRODES E 7018 The iron
14. dB A PLEASE NOTE the symbol Eb according to 2000 14 CE directive when with acoustic noise values indicates that the device respects noise emission limits 17 12 08 37299 GB CD LISA technical data CT 230 YSX CC CV MOSA REV 0 12 08 D C WELDING Duty cycle 210A 60 180 A 100 Welding current electronic regulation 20 210A Open circuitvoltage 65V C V WELDING Welding current 210 A 60 180 A 100 Welding voltage 15 30V STATIC CHARACTERISTIC 70 60 E 50 40 30 20 increasing N 10 10 90 100 150 200 210 250 SIMULTANEOUS UTILIZATION FACTORS In case Welding and Generation can be used simultaneously however the engine cannot be overloaded The table below gives the maximum limits to be respected ee 17 12 08 37299 GB CD MOSA 1 0 11 99 SYMBOLS IN THIS MANUAL MOSA The symbols used in this manual are designed to call your attention to important aspects of the operation of the machine as well as potential hazards and dangers for persons and things IMPORTANT ADVICE Advice to the User about the safety gt The information contained the manual can be changed without notice Potential damages caused in relation to the use of these instructions will not be considered because these are only indicative Remember that the non observance of the indications reported by us might cause damage
15. fueling Do not touch electric devices if you Do not smoke avoid flames sparks or electric tools when fueling are barefoot or with wet clothes Unscrew the cap slowly to let out the fuel vapours Always keep off leaning surfaces slowly unscrew the cooling liquid tap if the liquid must be topped up during work operations The vapor and the heated cooling liquid under pressure can burn face eyes skin static electricity can demage the arts on the circuit Do not fill tank completely Wipe up spilled fuel before starting engine ane hut off fuel of tank when moving machine where it is assembled An electric shock can kill Avoid spilling fuel on hot engine sparks may cause the explosion of battery vapours Www gt gt FIRST AID In case the operator shold be sprayed by accident from corrosive liquids hot toxic gas CHECKING BOARD or whatever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions Skin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor Suction of liquids from If you suppose that vomit has entered the lungs as in case of spontaneous vomit take the TL to the hospital with the utmost urgency Inhalation In case of exposure to high concentrat
16. out of the shipment packing Take out of the envelope A the user s manual B 2 Read the user s manual B the plates fixed on the machine the data plate 30 03 00 M3GB CD 5 TRANSPORT AND DISPLACEMENTS COVERED UNITS GE TS_ MOSA 1 0 01 01 In case you should transport or move the machine keep to the instructions as per the figures Make the transportation when the machine has no petrol in its tank no oil in the engine and and electrolyte in the battery Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conform to local rules and regulations Only authorized persons involved in the transport of the machine should be in the area of movement DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION ITIS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE model with no CTM accessory If you did not keep to the instructions you could damage the structure of the machine m O hum e e LO CD CISA ASSEMBLY MOSA 1 0 10 01 ATTENTION The CTM accessory cannot A removed from the machine and used separately actioned manually or following vehicles for the transport of loads or anyway for used different from the machine movements Note Lift the machine and assemble the parts as shown in the drawing 29 10 01 M6GB w M SA
17. regulations in force for electrical installations and safety 660 16 07 03 M20 R A GB rr 1 STARTING AND STOPPING THE ENGINE REV 0 12 08 CF MOSA Check daily Nea Do not alter the primary conditions of regulation and do not touch the sealed parts STARTING THE ENGINE Insert the electric protection device D lever towards above see page M37 OFF OS On Introduce the key Q1 turn it clockwise completely leaving it as soon as the engine starts Letthe engine run for some minutes before drawing the load CT 230 YSX CC CV STOPPING THE ENGINE c Before stopping the engine it is compulsory to effect the following operations stop to draw three single phase current from the auxiliary sockets Make sure that the unit is not supplying any power Disconnect the electrical protection device D lever downward Stop the engine turning the key Q1 it O counter clockwise OFF position then take it out c NB for safety reason the key must be kept by qualified personel If the engine fails to start do not insist for at least 15 seconds Space the further operations waiting for at least 4 minutes RUNNING IN During the first 50 hours of operation do not use more than 60 of the maximum output power of the unit and check the oil level frequently in any case please stick to the rules given in the engine use manual 17 12 08 37299 GB
18. said manual at disposal as well as that for the engine and alternator if the machine is synchronous and all other documentation about the machine GB Copyright We advise you to pay attention to the pages concerning the security See page 1 1 MUSA All rights are reserved to said Company It is a property logo of MOSA division of B C S S p A All other possible logos contained in the documentation are registered by the respective owners The reproduction and total or partial use in any form and or with any means of the documentation is allowed to nobody without a written permission by MOSA division of B C S S p A To this aim is reminded the protection of the author s right and the rights connected to the creation and design for communication as provided by the laws in force in the matter In no case MOSA division of B C S S p A will be held responsible for any damaga direct or indirect in relation with the use of the given information MOSA division of B C S S p A does not take any responsibility about the shown information on firms or individuals but keeps the right to refuse services or information publication which it judges discutible unright or illegal GE MS TS EAS 10 10 02 M1 01 GB GE_ MS_ TS_ INFORMATION Dear Customer We wish to thank you for having bought from MOSA a high quality set Our sections for Technical Service and Spare Parts will work
19. training in the correct application and use of the products to assure the security of the operator and protect the environment Regular inspections by ICIM to confirm that the requirements of the company s quality system and ISO 9001 are being respected All these advantages are guaranteed by the CERTIFICATE OF QUALITY SYSTEM No 0192 issued by ICIM S p A Milano Italy www icim it 10 10 02 M01 GB CD CISA 0 index CT 230 YSX CC CV MOSA REV 0 12 08 MO DESCRIPTION OF THE MACHINE M 01 QUALITY SYSTEM M 1 01 COPYRIGHT M 1 1 NOTES M 1 4 CE MARK M 1 5 TECHNICAL DATA 2 SYMBOLS SAFETY PRECAUTIONS 2 5 INSTALLATION AND ADVICE BEFORE USE M 2 6 INSTALLATION AND ADVICE M 2 7 INSTALLATION M3 UNPACKING M 4 1 TRANSPORT AND DISPLACEMENTS M 6 9 ASSEMBLY CTM 2 M 20 SET UP FOR OPERATION M 21 STARTING AND STOPPING THE ENGINE M 30 CONTROLS LEGEND M 31 CONTROLS 33 WELDING ANALOG CONTROL M 34 USE AS A WELDER M 37 USE AS A GENERATOR M 38 REMOTE CONTROL M 40 1 TROUBLE SHOOTING M 43 MAINTENANCE M 45 STORAGE M 46 CUST OFF 53 DIMENSIONS M 55 RECOMMENDED ELECTRODES M 60 ELECTRICAL SYSTEM LEGEND M 61 ELECTRICAL SYSTEM R 1 SPARE PARTS TABLES DT SPARE PARTS 17 12 08 37299 GB MOSA 1 0 10 02 N ATTENTION This use and maintenance manual is an important part of the machines in question The assistance and maintenance personel must keep
20. 1 CD Es spare PARTS LIST MOSA 10 0300 CF MOSA guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement of MOSA spare parts is required always ask for genuine parts only ts The requested data are to be found on the data plate located on the machine structure quite visible and easy to consult When ordering the spare parts it is recommended to indicate AE Europa 59 20090 CUSAGO MI ITALY 3942 90352 1 fax 39 02 90390466 1 serial number t ssszessse 2 model of welder and or generating set 3 n table 4 n position 5 quantity SJ O A TAVOLA RICAMBI SPARE PARTS PIECES DE RECHANGE ERSATZTEILE 3 4 13 48 18 17 16 20 21 22 o 1 11 21 22 23 ABBREVIATIONS AND SYMBOLS EV When ordering specify the engine type and the auxiliary voltage ER Engine with recoil starter only ES Engine with electric starter only VE E A S version only QM When ordering specify the length in meters VS Special version only SR By request only 14 12 986Q16M31 22 03 00 R1GB MOSA _ 0 12 08 CF Pi ces de rechange Ricambi MOSA spare parts CT 230 YSX CC CV ES 9 230V 110V version 1 2 3 4 5 6 7 IIT T 17 12 08 37299 Tavola ricambi GB Spare parts table CT 230 YSX CC CV
21. 2302280 GASKET L MT 1 qm 12 356721100 ROLL BAR 13 105112270 STRIP SEALING L MT 1 qm 14 HP0211046 INTAKE CHAMBER BULKHEAD 15 372859150 16 259109154 17 000037295 725 FOR MAINS 20 794004100 21 372808121 COVER FOR ELECTRICAL BOX 17 12 08 37299 GB 48016 90 70 90 230 5 CC CV 230 5 a gt hj e e o LO o o gt CO Ricambi O GB Spare parts MOSA Tavola ricambi MOSA GB Spare parts table CT 230 SX _ REv 0 04 05 CF Table pi ces de rechange Pos Rev Cod Descr Note 1 356708270 PERNO PER CERNIERA 2 356728005 CARENATURA 3 356728143 DEFLETTORE ARIA PER CAREN 4 309509005 GUARNIZIONE 5 372808115 MOLLA A GAS 6 307018024 TIRANTE 7 105112270 GUARNIZIONE L MT 1 qm 8 356708100 COPERCHIO FRONTALE 9 102302280 GUARNIZIONE L MT 1 qm 10 356728200 CASSONETTO ASPIRAZIONE 11 107300180 CHIUSURA COMPL A LEVA 12 343339601 MANIGLIA Pos Rev Cod Descr Note 1 356708270 HINGE PIN 2 356728005 COVER 3 356728143 AIR DEFLECTOR FOR COVER 4 309509005 GASKET qm 5 372808115 GAS SPRING 6 307018024 TIE ROD FOR COVER 7 105112270 STRIP SEALING L MT 1 qm 8 356708100 FRONT COVER 9 102302280 GASKET L MT 1 qm 10 356728200 INDUCTION CASE 11 107300180 LATCH 12 343339601 KNOB 06 04 05 37285 1 230 5
22. 66 0 J esoU MWJ dnu eufiseq 551 ATVLI IN ODWSND 0600Z exiwoez 100v xnv gt QU 10 309 uorqeuruou q oU Tp 03398014 euorzeuruoueq 104 UOTICITITPON Addy 1 ROTI TPOW CT 230 YSX CC CV V9L AOOV 5 i Y ICO oo HH Flake _ iagram ic 0 12 08 Schemas electriques CD Schema elettr Electr MOSA MOSA 230 5 CC CV pe i Y ico iagram ic d CD Schema elettr Electr MOSA 0 12 08 Schemas electriques MOSA uUOTZEZZIIOINE ens ezues 12193 O OTINPOTATI uoo TUTUISI e TS VSON YI 690 5 66222 8002 LL ZL N eoe1ode1 AO OOIXSA 062 LO _ wesouwwr dnu sumol 2551 og AWLI ODWSND 0600Z CUTYDDEN WSU ou abea Cold uorqeuruou q oU Tp 0339 014 uorzeuruou q eq ISeq UOTICITITPON 18847 SIG ejeq 454 g9 66cZ2 80 01 2
23. A OPERATIVE OPERATIVE UNITE Sede e Unit Viale Mazzini 181 20081 MI marchi BCS FERRARI PASQUALI Unit Operative Via Valbrina 17 19 42045 Luzzara RE marchi BCS FERRARI PASQUALI Viala Europa 58 20090 Cusago MI marchio MOSAJ E CONFORME ALLA HORUM COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2000 PER LE SEGUENTI ATTIVITA FOR THE FOLLOWING ACTIMTIES EA 18 ed assislonza di tra tori macchine verde Progettazione produzione ed assistenza di motosaldatrici e gruppi elattrogeni Design production and servicing of Fanors agricullural and green maintenance machinas Design production and servicing of engine driven woldors and generating sets Fear ad amare sola calis pae fappicabilo Ga record oba crema 3000 f r DD Ey of application ROOT 2000 meurent 3 pene jon lad del campane gay Lud scadere Esprng dala 05 03 2009 d per ka __ _ Fu P Put cp gf Gurren X The advantages for MOSA clients are Constant quality of products and services at the high level which the client expects Continuous efforts to improve the products and their performance at competitive conditions Competent support in the solution of problems e Information and
24. ATVLHIN ODWSND 0600Z elly Y uu BMG euojeufesiq SIC 5 A3 3v 0011 gt S 0 uogeuiwouag Deg eq MOTISA OTIVIO A 3IIHWOONVI8 M pv z 899822 2410 u 35 oid gt JO 159 NI3Y9 30Y3A MEN addy sig ejeq ILIHMW NIIH9O 5 W TN 90022072 OONvIg aqudgA Q3H OSSOH Y Ya gt 90109 o Tis 9 O 49 5 62 O ian mE A3HO I p I MOV IS OH3N i i ca I I XU lt o EZ 22 O L 19 l rs a t 3079 0719 Q38 OSSOMH 4 4 I I C 1 2 090 Q 2 voz YS LIU CIO COGI ADD YALYVLS o o e SEE 555 9 i O 1 0 27123 21 0 2 Y i 340 9 b er 15 2 cc MOSA O MOSA 89 66225 80 61 21 2022110306 ens ezues TZ19 OTINPOTATI uoo aquasaza Y TS VSONW N 0
25. CISQNCIM hereby certify that the organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 1 20081 Abbiategrasso MI BCS FERRARI PASQUALI Trade Marks Operative Units Via Valbrina 17 19 42045 Luzzara RE BCS FERRARI PASQUALI Trade Marks Viale Europa 59 20090 Cusago MI Mosa Trade Mark for the following field of activities Design production and servicing of tractors agricultural and green maintenance machines Design production and servicing of engine driven welders and ganorating sats has implemented and maintains a Quality Management System which fulfills the requirements of the following standard 150 9001 2000 Issuedon 2006 03 06 Validity date 2009 03 05 Registration Number T 3722 Fi S Fabio Roversi President of IQNet IQNet Farmers AENOR AFAQ France AIR Vingocte Intemational Belgien ANCE Mento Porngal COC China COM China CSQ Czech Republic Cro Cert Comit DOS Germany DS Denmark ELOT Greece FCAV Brazil FONDONORMA Foneziela Hong ICONTEC Colombia IMINC IRAM Argentina Japan KEMA Korea MSZT Hungary Nemko Certification Norway NSAID Ireland OQS Austria PCBC Poland PSB Certification Singapore RE Asia SAI Global SFS Finland SI Irae a Slovenia SOS Switzerland SRAC Romania TEST Sr Petersburg Russia US Serbis and Monte Mia represen
26. D 30 372855400 PONTE CHOPPER 250A CHOPPER BRIDGE 250A 31 372858248 PIANALE SCATOLA ELETTRICA ELECTRIC BOX 33 734517032 PIASTRINA RIDUZIONE REDUCTION FOR SOCKET 32A 16A 34 305907270 PRESA 16 400V 3P N T EEC SOCKET 16A 400V 3P N T 35 307017240 PRESA 220V 16A EEC SOCKET 16A 220V 2P T 36 259107241 PRESA SCHUKO 16A 230V 2P T SOCKET SCHUKO 16A 230V 2P T 37 306467107 DISGIUNT TERMICO 20AMP 250 V THERMOPROTECTION 20 250 V 38 105111540 Vedi Cod 219937105 See part no 219937105 39 3 2987020 PANNELLO FRONTALE FRONT PANEL 40 102044400 PRESA DI SALDATURA WELDING SOCKET 41 102301310 PRESA DI SALDATURA WELDING SOCKET 42 3 2959860 SCHEDA FILTRO ANTIDISTURBI ANTI JAMMING FILTER PCB 17 12 08 37299 GB MOSA CO Ricambi M GB Spare parts REV 0 04 05 CF Pi ces de rechange CT 230 SX 06 04 05 37285 1 MOSA MOSA REV2 12 08 Pos Rev Cod 1 372802038 2 372803036 5 272506010 4 105111290 9 6050090 1001070 7 1018100 9 107011280 9 372803030 10 372803025 10 372853025 11 232123040 12 372802200 12 0152200 12 356402200 13 372802212 14 356321035 15 105913045 16 372803101 Rev Cod 1 372802038 2 372803036 5 272506010 4 105111290 9 6050090 1001070 7 1018100 9 107011280 9 372803030 10 372803025 10 372853025 11 232123040 12 372802200 12 0152200 12 356402200 13 372802212 14 356321035 15 105913045 16 372803101 CD Tavola ricambi Sp
27. are parts table REv 2 12 08 CF Table pi ces de rechange Descr RONDELLA DI BLOCCAGGIO TIRANTE ALBERO ROTORE CONVOGLIATORE ARIA VENTOLA CON FASCETTA ANELLO ELASTICO CUSCINETTO ANELLO OR TIRANTE ALBERO CON ROTORE STATORE STATORE AVV 400T230M110CTE 48M FLANGIA ATTACCO MOTORE MOTORE YANMAR L100AE DEG MOT YANMAR L100AE DEG MOT YANMAR L100N TUBO SCARICO OLIO ANTIVIBRANTE FLANGIA PORTA ALTERNATORE SUPPORTO ALTERNATORE Descr STOP WASHER SHAFT ENGINE TIE ROD AIR DUCT FAN RING BEARING OR RING TIE ROD SHAFT WITH ROTOR STATOR STATOR FLANGE FIXING ENGINE YANMAR ENGINE L100AE DEG YANMAR ENGINE L100AE DEG YANMAR ENGINE L100N OIL EXHAUST PIPE VIBRATION DAMPER FLANGE ALTERNATOR HOLDER ALTERNATOR SUPPORT CT 230 SX fino a REV 0 04 05 Del 26 06 01 03 06 da REV 1 07 06 Del 26 06 01 03 06 fino a REV 0 04 05 Del 26 06 01 03 06 da REV 1 07 06 Del 26 06 01 03 06 fino a REV 1 07 06 Del 44 08 25 02 08 da REV 2 12 08 Del 44 08 25 02 08 up to REV 0 04 05 Del 26 06 01 03 06 from REV 1 07 06 Del 26 06 01 03 06 up to REV 0 04 05 Del 26 06 01 03 06 from REV 1 07 06 Del 26 06 01 03 06 up to REV 1 07 06 Del 44 08 25 02 08 from REV 2 12 08 Del 44 08 25 02 08 06 04 05 37285 1 g9 66cZ2 80 01 21 230 5 CC CV 377 VO VA urs 2 PAY 2 7 4 C 0 1 11 2 S 5 4 ESE LIS
28. areas access of which is forbidden to unqualified personel are the control switchboard front the exhaust of the endothermic engine c At the beginning of every work check the electric parameters and or the controls placed on the front Make sure that the ground connection 12 is efficent keep to installation local rules and or to national laws in order to integrate or ensure the working of varius electric protection devices referring to the several distribution system TT TN IT operation unnecessary for machine with isometer See page M 20 21 Check the voltmeter N shows the voltage three or single phase has to be drawn Indicative no load voltage 230V 400V Connect up the machine using proper plugs and cables in good condition to the AC socket 15 to draw single or three phase power or by cables with adeguate section to the terminal board placed inside the derivation box Q3 Nominal voltage Using several sockets at tha same time the maximum power possible is that indicated on the data plate The max continuous power of the generating set or the load current must not be exceeded 230 YSX CC CV THERMAL CIRCUIT BREAKER TBC CIRCUIT BREAKER BC If you overload the generator the TBCs or BCs will automatically switch off lf the protection is released disconnect all the connected loads MP CLOSED OPEN THERMAL CIRCUIT BREAKER CIRCUIT BREAKER Reset the
29. at best to help you if it were necessary To this purpose we advise you for all control and overhaul operations to turn to the nearest authorized Service Centre where you will obtain a prompt and specialized intervention In case you do not profit on these Services and some parts are replaced please ask and be sure that are used exclusively original MOSA parts this to guarantee that the performances and the initial safety prescribed by the norms in force are re established ts The use of non original spare parts will cancel immediately any guarantee and Technical Ser vice obligation from MOSA NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively Follow the instructions contained in it in this way you will avoid inconveniences due to negligence mistakes or incorrect maintenance The manual is for qualified personnel who knows the rules about safety and health installation and use of sets movable as well as fixed You must remember that in case you have difficulties for use or installation or others our Technical Service is always at your disposal for explanations or interventions The manual for Use Maintenance and Spare Parts is an integrant part of the product It must be kept with care during all the life of the product In case the machine and or the set should be yielded to another user this manual must also given to him Do not damage it do not take parts away do not
30. ating conditions frequent stops and starts dusty environment cold weather extended periods of no load operation fuel with over 0 5 sulphur content do maintenance more frequently BATTERY WITHOUT MAINTENANCE DO NOT OPEN THE BATTERY The battery is charged automatically from the battery charger circuit suppplied with the engine Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced THE ENGINE PROTECTION NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHARGED REGULARLY AT INTERVALS AS PRESCRIBED THE OWNER S ENGINE MANUAL 05 09 05 M43GB CD STORAGE 1 0 06 00 In case the machine should not be used for more than 30 days make sure that the room in which it is stored presents a suitable shelter from heat sources weather changes or anything which can cause rust corrosion or damages to the machine MOSA MOSA 3 Have qualified personnel prepare the machine for storage GASOLINE ENGINE Start the engine It will run until it stops due to the lack of fuel Drain the oil from the engine sump and fill it with new oil see page M25 Pour about 10 cc of oil into the spark plug hole and screw the spark plug after having rotated the crankshaft several times Rotate the crankshaft slowly until you feel a certain compression then leave it I
31. attery voltmeter Remote control socket Button indicating light 20 11 PTO HI Commutator switch serial parallel Thermal magnetic circuit breaker Selection push button 20 1 1 PTO HI Water temperature indicator 10 05 01 M30 GB e e e gt lt y gt eB e E K on eo os 5 6 o e 9 5 E lt ooo DI gt gt 230V 110V version Q1 59 1 M1 1 g9 66cZ2 80 01 21 Schuko version MOSA Operating REV 0 12 08 CF After having prepared the machine put in oil and fuel the machine is ready for operation MOSA Before starting the engine please note the following e The welder should only be operated by qualified personnel with experience in working with engine driven welders e Check the oil level daily Fuel should be put in before starting the engine e Before using the welder or the auxiliary power let the engine warm up and before stopping the engine let it run without load to cool down Refer to the following instructions regarding the function of the various controls on the front panel Controls and Instruments Remote control connection The optional RC remote control is used to control the current or voltage at a distance When the switch 15 pointing toward the remote control co
32. chopper supply PCB Switch and leds PCB Hall sensor Water heather indicator Battery charge indicator Transfer pump selector AUT 0 MAN Fuel transfer pump GECO generating set test Hooting with level switches Voltmeter regulator WELD AUX switch Reactor 3 phase Switch disconnector solenoid stop timer VODIA connector F EDCA connector OFF ON DIAGN selector DIAGNOSTIC push button DIAGNOSTIC indicator Welding selector mode load 230V 1 phase plug V Hz analogic instrument Engine protection EP6 G F I relay supply switch Radio remote control receiver Radio remote control trasnsmitter Isometer test push button Remote start socket Transfer fuel pump control Ammeter selector switch 400V 230V 115V commutator 90 60 Hz switch Cold start advance with temp switch SIART STOP switch Polarity inverter two way switch Engine protection 7 AUTOIDLE switch AUTOIDLE PCB A4E2 ECM engine Remote emergency stop connector V A digital instruments and led VRD PCB Water in fuel 26 07 04 M60GB 1 58 6 90 70 90 9UOIZEZZUO Ne ens 22195 1219 e o uoo ep eyeudoud abba Ip IS VSON 87 YY oer y 010 5 0827 lt 0002 20 82 7 XS 062121 Pp yesourWWWJ dyu eunpew
33. contained in the coating increases the quality of metal added Good mechanical properties Weld in all position Electrode holder at inverse polarity Wid deposit of nice aspect also vertical Workable high yield Suitable for steels with high contens of sulphur impurities CELLULOSIC ELECTRODES E 6010 Cellulosic electrodes weld only in d c with polarity electrode holder ground clamp Special for steels run on pipes with R max 55 kg mm Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS 2 digits type of coating and electric power conditions see table 3 1 digits welding positions see table 2 Li Descrizione 2 3 digits tesile strenght of 9 Cellulose electrodes for d c the weld deposit see table 1 Cellulose electrodes for a c symbol for Rutile electrode for d c Coated Rutile electrode for a c electrode High yield rutile electrodes T 60 000 70 000 Basic electrodes for d c Basic electrodes for c a High yield basic electrodes for d c inverse polarity Acid electrodes for flat or front position welding for d c pole and for a c High yield rutile electrodes for flat or front plane position welding for d c and a c High yield acid electrodes for flat or front plane position welding for d c pole and a c High yield basic electrodes for flat or front plane Table 1 position welding for d c inverse polarity Extra high yield ac
34. ding area Do not weld on containers which contain flamable material Do not weld near refuelling areas Do not weld on easily flamable surfaces Do not use the welder to defrost thaw pipes Remove the electrode from the electrode holder when not welding Avoid inhaling fumes by providing a ventilation system or if not possible use an approved air breather Do not work in closed areas where there is no fresh air flow Protect face and eyes protective mask with suitable dark lens and side screens ears and body non flamable protective clothers 30 03 00 M2 5GB CD INSTALLATION AND ADVICE REV 1 06 07 CF MOSA MOSA INSTALLATION AND ADVICE BEFORE USE GASOLINE ENGINES m Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area DIESEL ENGINES m Use in open space air swept or vent exhaust gases far from the work area POSITION Place the machine on a level surface at a distance of at least 1 5 m from buildings or other plants Maximum leaning of the machine in case of dislevel A 20 max 10 Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature Make sure that the machine does move during the work block it possibly with tools and or devices made to this purpose
35. e with only safety material It is prohibited to use water to quench fires on the electric machines Use only with non inserted voltage It is prohibited to make interventions before having disinserted the voltage No smoking It is prohibited to smoke while filling the tank with fuel No welding It is forbidden to weld rooms containing explosive gases ADVICE No harm for persons and things Use only with safety tools adapted to the specific use It is advisable to use tools adapted to the various maintenance works Use only with safety protections specifically suitable It is advisable to use protections suitable for A the different welding works Use only with safety protections It is advisable to use protections suitable for the different daily checking works y x 1 a Use only with safety protections it is advisable to use all protections while A shifting the machine Use only with safety protections It is advisable to use protections suitable for the different daily checking works and or maintenance 26 11 99 M2 1GB CD amp INSTALLATION AND ADVICE BEFORE USE GE MS TS MOSA 1 0 06 00 A The installation and the general advice concerning the operations are finalized to the correct use of the machine in the place where it is used as generator group and or welder stop engine when
36. f low oil pressure or engine high temperature The system consist of electronic card of control and check and of an engine stop device solenoid ElettroStop electrovalve ElettroValvola The device enter in operation when the engine starts and in case of low oil pressure and high temperature will stop the machine and show the cause of the stop with the warning light of high temperature or low oil pressure In case of low oil pressure check the level and if it is correct call the Service Station In case of high temperature make sure that there are no leaves and or pieces of material obstructing the air ducts N B if the unit is used as a generator in hot climates and with loads near to the maximum the protection device can be triggered off please reduce the load of the engine Once the cause of the problem is removed to reset the protection it is enough to report the ignition key Q1 on OFF position and start the engine again 1 1 M k lai High temperature SZ Low oil pressure THE ENGINE PROTECTIONS DO NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHANGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 07 05 01 M39GB CD MOS TROUBLE SHOOTING 1 0 04 04 PROBLEM No welding current but auxiliary output is OK MOSA Weld poorly Intermittently welds poorly No welding output and n
37. f the several components for a further reutilization or for getting rid of them the eventual packing and transportation of the eliminated parts up to their delivery to the store or to the bureau encharged to the cust off or to the storage office etc The several operations concerning the cust off involve the manipulation of fluids potentially dangerous such as lubricating oil and battery electrolyte The dismantling of metallic parts liable to cause injuries or wounds must be made wearing heavy gloves and using suitable tools The getting rid of the various components of the machine must be made accordingly to rules in force of law a o local rules Particular attention must be paid when getting rid of lubricating oils battery electrolyte and inflamable liquids such as fuel cooling liquid The machine user is responsible for the observance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its components In case the machine should be cust off without any previous disassembly it is however compulsory to remove tank fuel engine lubricating oil cooling liquid from the engine battery NOTE MOSA is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization GE_ MS_ TS_ In case of necessity for first aid and fire prevention see page M2 5 N IMPORTANT In the
38. g Measured acustic power 92 LWA 67 dB A 7 Guaranteed acustic power 93 LWA 68 dB A 7 m Yi Dimensions and weight are inclusive of all parts without wheels and towbar POWER Declared power according to ISO 3046 1 temperature 25 C 30 relative humidity altitude 100 m above sea level Its admitted overload of 10 each hour every 12 h In an approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 C ACOUSTIC POWER LEVEL ATTENTION The concrete risk due to the machine depends on the conditions in which it is used Therefore it is up to the end user and under his direct responsibility to make a correct evaluation of the same risk and to adopt specific precautions for instance adopting a I P D Individual Protection Device Acoustic Noise Level Lwa Measure Unit dB A it stands for acoustic noise released in a certain delay of time This is not submitted to the distance of measurement Acoustic Pressure Lp Measure Unit dB A it measures the pressure originated by sound waves emission Its value changes in proportion to the distance of measurement The here below table shows examples of acoustic pressure Lp at different distances from a machine with Acoustic Noise Level Lwa of 95 dB A Lp 1 meter 95 dB A 8 dB A 87 dB A Lp a 4 meters 95 dB A 20 dB A 75 dB A Lp 7 meters 95 dB A 25 dB A 70 dB A Lp 10 meters 95 dB A 28 dB A 67
39. he level indicated on the filter Do not smoke or use open flames during refuelling operations in order to avoid explosions or fire hazards Fuel fumes are highly toxic carry out operations outdoors only or in a well ventilated environment Avoid accidentally spilling fuel Clean any eventual leaks before starting up motor Refill the tank with good quality diesel fuel such as automobile type diesel fuel for example For further details on the type of diesel fuel to use see the motor operating manual supplied Do not fill the tank completely leave a space of approx 10 mm between the fuel level and the wall of the tank to allow for expansion In rigid environmental temperature conditions use special winterized diesel fuels or specific additives in order to avoid the formation of paraffin GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a differential switch circuit breaker In these groups the generator star point is generally connected to the machine s earthing by employing the TN or TT distribution system the differential switch guarantees protection against indirect contacts In the case of powering complex installations requiring or employing additional electrical protection devices the coordination between the protection devices must be verified For the grounding connection use the terminal 12 comply to local and or current
40. id electrodes extra high penetration if required for flat position welding only for d c pole and a c 80 000 90 000 100 000 110 000 120 000 for all positions for plane and verticl for plane posotion only Table 2 Table 3 10 10 03 M55GB CD MOS A o ELECTRICAL SYSTEM LEGENDE REV 6 06 08 CF Alternator Wire connection unit Capacitor Welding PCB transformer Fuse 400V 3 phase socket 230V 1phase socket 110V 1 phase socket socket warning light Hour counter Voltmeter Welding arc regulator 230V 3 phase socket Welding control PCB Welding current ammeter Welding current regulator Current transformer Welding voltage voltmeter Welding sockets shunt D C inductor Welding diode bridge MOSA lt gt x lt m m Q Z gt 1 Arc striking resistor B1 Arc striking circuit C1 110V D C 48V D C diode bridge D1 E P 1 engine protection E1 Engine stop solenoid F1 Acceleration solenoid G1 Fuel level transmitter H1 Oil or water thermostat 1 48V D C socket L1 Oil pressure switch M1 Fuel warning light N1 Battery charge warning light 01 Oil pressure warning light P1 Fuse Q1 Starter key R1 Starter motor 51 Battery T1 Battery charge alternator U1 Battery charge voltage regulator V1 Solenoid valve control PCBT Z1 Solenoid valve W1 Remote control switch X1 Remote control and or wire feeder socket Y1 Remote control plug
41. ing sockets turnning them clockwise to lock them in position PUSH AND TWIST c Make sure that the ground clamp whose cable must be connected to the or terminal depending on the type of electrode makes a good connection and is near to the welding position Pay attention to the two polarities of the welding circuit which must not come in electric contact between themselves REMOTE CONTROL RC See page M 38 CT 230 YSX CC CV N ATTENTION To reduce the risk of electromagnetic interferences use the minimum lenght of welding cables and keep them near and down ex on the floor The welding operations must take place far from any sensitive electronic device Make sure that the unit is earthed see M20 In case the interference should last adapt further disposition such as move the unit use screened cables line filters screen the entire work area In case the above mentioned operations are non sufficient please contact our Thechnical Assistance Service With a welding cable length up to 20 m is suggested a section of 35 mm with longer cables a bigger section is required 17 12 08 37299 GB j USE AS GENERATOR REV 0 12 08 CF t Itis strictly forbidden to connect the group to the public mains a o to another source of electric power Sockets not self locked voltages are avaible immediately after starting also with no plugs MOSA The
42. ion of vapours take immediately to a non polluted zone gt person involved gt FIRE PREVENTION In case the working zone for whatsoever cause goes on fire with flames liable to Cause severe wounds or death follow the first aid as described by the ruling norms or local ones EXTINCTION MEANS Appropriated arbonate anhydride or carbon dioxyde powder foam nebulized water ot to be used Avoid the use of water jets Other indications over eventual shedding not on fire with foam or sand use water jets to cool off the surfaces close to the fire articular protection ear an autorespiratory mask when heavy smoke is present Useful warnings Avoid by appropriate means to have oil sprays over metallic hot surfaces or over electric ontacts switches plugs etc In case of oil sprinkling from pressure circuits keep in mind that the inflamability point is very low THE MACHINE MUST NOT BE USED IN AREAS WITH EXPLOSIVE ATMOSPHERE 10 06 00 2 CD MIOS A PRECAUTION ENGINE DRIVEN WELDER GE MS TS MOSA 10 0300 CF INSTALLATION AND ADVICE BEFORE USE The operator of the welder is responsible for the security of the people who work with the welder and for those in the vicinity The security measures must satisfy the rules and regulations for engine driven welders The information given below is in addition to the local security norms Estimate possible electromagnetic problems in the work area taking into acc
43. it EP2 E A S connector Exclusion indicating light PTO HI Auxiliary current push button Fuel level light E A S PCB Control unit for generating sets QEA Ground fault interrupter 30 mA Engine control unit and economiser Ammeter Frequency meter Fuse Stop switch Warning light high temperature Arc Force selector Fuel level transmitter Voltage commutator Fuel electro pump Engine control unit EP7 48V A C socket Welding scale switch Preheating indicator Y A switch Start Local Remote selector AUTOIDLE switch A C output indicator Emergency button Choke button Hour counter Warning level light Contactor Engine control unit 5 CC CV switch Voltmeter Battery charge warning light Thermal magnetic circuit breaker Ground fault interrupter Pre heat push button Connector wire feader Oil pressure warning light Oil alert Welding arc regulator Starter key Derivation box Battery charge sockets Welding selector mode Siren Welding ammeter Battery Engine control unit EP4 Wire feeder supply switch Plug 230V singlephase Welding current regulator Dirty air filter warning light indicator Earth leakage relay Analogic instrument V Hz Current trasformer R P M adjuster Polarity inverter remote control Relase coil Engine control unit EP6 Welding voltage voltmeter Polarity inverter control Oil pressure indicator Remote control switch Selection push button 30 1 1 PTO HI B
44. ltage There can be parts in voltage dangerous to touch The non observance of the advice implies life danger FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces If the advice is not respected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not respected there can be explosions WATER Danger of shortcircuit If the advice is not respected fires or damage to persons can be caused SMOKING The cigarette can cause fire or explosion If the advice is not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosions with damage to persons or things WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons PRESSION Danger of burns caused by the expulsion of hot liquids under pressure ACCES FORBIDDEN to non authorizad peaple pP P PP P P pibe SYMBOLS AND SAFETY PRECAUTIONS GE_ MS_ TS PROHIBITIONS No harm for persons Use only with safety clothing It is compulsory to use the personal protection means given in equipment Use only with safety clothing It is compulsory to use the personal protection means given in equipment Use only with safety protections Itis a mustto use protection means suitable for the different welding works Us
45. n case the battery for the electric start is assembled disconnect it Clean the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in o dry place DIESEL ENGINE For short periods of time it is advisable about every 10 days to make the machine work with load for 15 30 minutes for a correct distribution of the lubricant to recharge the battery and to prevent any possible bloking of the injection system For long periods of inactivity turn to the after soles service of the engine manufacturer Clean the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in a dry place GE MS TS In case of necessity for first aid and of fire prevention see page M2 5 IMPORTANT In the storage operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place i 69 O6 30 00 00 M45GB gt Have qualified personnel disassemble the machine and dispose of the parts including the oil fuel etc in a correct manner when it is to be taken out of service As cust off we intend all operations to be made at utilizer s care at the end of the use of the machine This comprises the dismantling of the machine the subdivision o
46. nnector the current voltage is regulated by the remote control When the switch is OFF the current voltage is regulated by the front panel potentiometer LOCAL PUSH AND REMOTE SCREW TIGHT Front panel control regulates welding current Remote control regulates welding current Welding cable connections For direct current electrode positive connect work cable to negative terminal and electrode holder to positive terminal For direct current electrode negative reverse cable connections gt Make sure that the ground clamp makes a good connection and is near the welding position CT 230 YSX CC CV PUSH AND SCREW TIGHT welding sockets welding cable connector Auxiliary power outlets The unit is equipped with auxiliary output sockets The voltages depend on the version selected The three phase socket where it is mounted requires no protection as the asynchronous alternator protects itself The single phase sockets are always protected with Circuit Breakers CB or Thermal Circuit Breakers TCB The TCBs have a push button that pops out when overloaded the CBs have a lever that gets down when overloaded After they have been activated they need a short time to cool down out then they can be re inserted If the TCB or CB continue to pop out check that the load is not too large for the output of the socket circuit breakers thermal circuit breaker PUSH AND TWIST Ground fault inter
47. o auxiliary power output L POSSIBLE CAUSE 1 Defective diode bridge 1 Defective diode bridge 1 Short circuit in wiring 2 Defective condenser 3 Defective stator 4 Short circuited diode bridge only for models with electronic control of welding current WHAT TO DO 1 Check the diodes of the bridge p 8 the remote control switch in thd internal position Check diodes and SCR s of thd bridge H Check the transformer which supplies power to the welding control PCB If is OK replace the 1 Check the open circuit welding voltage If it is OK the diode bridge is OK If it is 1 3 or 2 3 of the nominal value check the diodes or the SCR s connectors clean and making good contact Check that shunt connections are tight 5 2 Replace the welding current control PCB 1 Check the wiring inside the welder for a short circuit between cables or to ground 2 If the wiring is OK short circuit the condenser to be sure that it is discharged disconnect all wires from condenser and using ohmmeter check that the condenser is not short circuited 3 If the condenser box is OK disconnect all leads from the stator except for those going to the condenser box and check the output from the alternator If there is no output from the welding winding and the auxiliary winding replace the stator 4 If there is output from all windings reconnec
48. o occasional damages and the replacement of electric and mechanic components consumed in normal use by the Assistance Authorized Center as well as by MOSA The replacement of tires for machines equipped with trolleys must be considered as repair since it is not delivered as standard equipment any lifting system The periodic maintenance should be performed according to the schedule shown in the engine manual An optional hour counter M is available to simplify the determination of the working hours IMPORTANT In the maintenance operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place AA Use suitable tools and clothes e Do not modify the components if not authorized HOT surface can hurt you ENGINE and ALTERNATOR PLEASE REFER TO THE SPECIFIC MANUALS PROVIDED VENTILATION Make certain there are no obstructions rags leaves or other in the air inlet and outlet openings on the machine alternator and motor ELECTRICAL PANELS Check condition of cables and connections daily Clean periodically using a vacuum cleaner DO NOT USE COMPRESSED AIR DECALS AND LABELS All warning and decals should be checked once a year and replaced if missing or unreadable STRENUOUS OPERATING CONDITIONS Under extreme oper
49. ostat Choke solenoid Step relay Circuit breaker Battery charge sockets Sensor cooling liquid temperature Sensor air filter clogging Warning light air filter clogging Polarity inverter remote control Polarity inverter switch Transformer 230 48V Diode bridge polarity change Base current diode bridge PCB control unit polarity inverter Base current switch Auxiliary push button ON OFF Accelerator electronic control Actuator Pick up Warning light high temperature Commutator auxiliary power 24V diode bridge Y s commutator Emergency stop button Engine protection EPS Pre heat push button Accelerator solenoid PCB Oil pressure switch Water temperature switch Water heater Engine connector 24 poles Electronic GFI relais Release coil circuit breaker Oil pressure indicator Water temperature indicator Battery voltmeter Contactor polarity change Commutator switch series parallel Commutator switch Key switch on off QEA control unit Connector Frequency rpm regulator Arc Force selector Device starting motor Fuel electro pump 12V c c Start Local Remote selector Choke button Switch CC CV Connector wire feeder 420V 110V 3 phase transformer Switch IDLE RUN Hz V A analogic instrument EMC filter Wire feeder supply switch Wire feeder socket DSP chopper PCB Power
50. ount the following indications Telephonic wirings and or of communication check wirings and so on in the immediate vicinity Radio and television receptors and transmettors Computer and other checking devices Critical devices for safety and or for industrial checks Peapol who for instance use pace maker hearing aid for deaf or something and else Devices used for rating and measuring The immunity of other devices in the operation area of the welder Make sure that other used devices are compatible If it is the case provide other additional measures of protection 8 The daily duration of the welding time PRE A ATTENTION Make sure that the area is safe before starting any welding operation Do not touch any bare wires leads or contacts as they be live and there is danger of electric shock which can cause death or serious burns The electrode and welding cables etc are live when the unit is operating Do not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes Insulate yourself from the work surface while welding Use carpets or other insulating materials to avoid physical contact with the work surface and the floor Always wear dry insulating glovers without holes and body protection Do not wind cables around body m Use ear protections if the noise level is high Keep flamable material away from the wel
51. rupter The ground fault interrupter protects the operator from injury in the event of a ground fault Turn on the GFI ground fault interrupter D by pushing it upwards Instruments Standard instruments include an operating hour counter and a voltmeter for the auxiliary power which shows the three phase voltage 400V or single phase 230V If the voltmeter does not show any voltage check that GFI ground fault interrupter is inserted The voltage shown will vary depending on the load and the welding current being drawn At no load and when not welding the voltages can be highter than the nominal values 440V 250V The auxiliary power cannot be used when it drops below 360V three phase 200V 100V single phase 0000101 h auxiliary operating power hours voltmeter 17 12 08 37299 GB lt OSA USE AS WELDER REV 0 12 08 MOSA This symbol Norm EN 60974 1 security standards for arc welders signifies that the welder can be used in areas with increased risk of electrical shock N ATTENTION The areas access of which is forbiden to unqualified personel are the control switchboard front the exhaust of the engine the welding process Check at the beginning of each work the electric parameters and the controls placed on the front panel Make sure the unit is properly grounded 12 where it is assembled See page M20 Fully insert the welding cable plugs into the correspond
52. t the diode bridge and check if there is welding current If not the diode bridge is defective If there is welding current connect the auxiliary power leads one at a time until there is no output at this point the short circuit is in that line 06 04 04 40 1 OSA GB MAINTENANCE 10 09 05 CF Have qualified personnel maintenance and troubleshooting work Stop the engine before doing any work inside the machine If for any reason the machine must be operated while working inside pay attention moving parts hot parts exhaust manifold and muffler etc electrical parts which may be unprotected when the machine is open e Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete MOVING PARTS can injure See pag 1 1 NOTE By maintenance at care of the utilizer we intend all the operatios concerning the verification of mechanical parts electrical parts and of the fluids subject to use or consumption during the normal operation of the machine For what concerns the fluids we must consider as maintenance even the periodical change and or the refills eventually necessary Maintenance operations also include machine cleaning operations when carried out on a periodic basis outside of the normal work cycle The repairs cannot be considered among the maintenance activities i e the replacement of parts subject t
53. ted m the USA the Following AGB Vineotte International DOS KEMA NSAL and SAI Global list of et partners ix valid at the time of issue of this eertifocate Updated information is available under wow ignet certification com uel 4 Gianrenzo Prati President of CISQ S UNI EN ISO 9001 2000 150 9001 2000 0192 MOSA has certified its quality system according to UNI EN ISO 9001 2000 to ensure a constant high quality of its products This certification covers the design production and servicing of engine driven welders and generating sets The certifying institute which is a member of the International Certification Network IQNet awarded the official approval to MOSA after an examination of its operations at the head office and plant in Cusago Italy This certification is not a point of arrival but a pledge on the part of the entire company to maintain a level of quality of both its products and services which will continue to satisfy the needs of its clients as well as to improve the transparency and the communications regarding all the company s actives in accordance with the official procedures and in harmony with the MOSA Manual of Quality GE 5 TS EAS CERTIFICATO n CERTIFICATE No 0192 4 ISI CERTIFICA CHE L SISTEMA DI GESTIONE PER LA QUALITA DI WE HERES CERTIFY THAT THE QUALITY MANAGEMENT SYSTEM OPERATED BY BCS S p A UNT
54. tential intervention will fall on the executioner as in fact he becomes maker of the machine Notice this manual does not engage MOSA who keeps the faculty apart the essential characteristics of the model here described and illustrated to bring betterments and modifications to parts and accessories without putting this manual uptodate immediately 10 10 02 M 1 1 GB CD o ce mark MOSA _ 4 10 07 CF Any of our product is labelled with CE marking attesting its conformity to appliable directives and also the fulfillment of safety requirements of the product itself the list of these directives is part of the declaration of conformity included in any machine standard equipment Here below the adopted symbol CE marking is clearly readable and unerasable and it can be either part of the data plate A or placed as a sticker near the data plate B gt Wee Europa 59 20090 CUSAGO ITALY 5 0 CS A N tel 39 02903521 fax 39 0290390466 Vle Europa 59 20090 CUSAGO MI ITALY http e mai infoemosa it 38 02903521 fax 39 0290390466 tel 48 in VESTALY TYPE http www mosait e mail infoemosa it i N Uo 9 5 Emi JN _ n PC RPM_ ____ 100 Furthermore each model it is shown the noise level value the symbol used is the following db
55. to persons or things It is understood that local dispositions and or laws must be respected WARNING Situations of danger no harm to persons or things Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine SYMBOLS AND SAFETY PRECAUTIONS GE_ MS_ TS SAFETY PRECAUTIONS A DANGEROUS This heading warns of an immediate danger for persons as well for things Not following the advice can result in serious injury or death This heading warns of situations which could result in injury for persons or damage to things A CAUTION To this advice can appear a danger for persons as well as for things for which can appear situations bringing mate rial damage to things A A These headings refer to information which will assis you in the correct use of the machine and or accessories 26 11 99 M2GB CD MOSA 1 1 04 03 SYMBOLS for all MOSA models MOSA STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE If the advice is not respected damage can happen to persons or things HIGH VOLTAGE Attention High Vo
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