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GE 85 SKID - PSX - PMSX GE 115 SKID - PSX - PMSX

Contents

1. M SA Set up for operation 1 1 09 05 CF MOSA i 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 TA LUBRICANT RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products 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 oil 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 TS DSP Water cooled systems AIR FILTER 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 Hi FUEL Do not smoke or use open flames during refuelling operations in orde
2. 12 06 03 M37GB 15000 GE CD LI Es A tem 35 REMOTE CONTROL OMOSA 1 0 03 06 3 The selector LOCAL START REMOTE START 16 of the generating set must be switched on LOCALSTART Put the selector switch board N7 on ON The coupling of the TCM 35 with the generating set ready for remot starting permits to work far from the set itself The remote control is connected to the front plate X1 and or rear plate with a multiple connector N B The remote control TCM 35 can be used only with machines equipped with control and protection device EP6 07 For use of TCM 35 see page 21 start and stop of this manual TELECOMANDO REMOTE CONTROL 06 02 03 M38 GB CD PROTECTIONS 1 0 05 01 OSA Don not intervene on the setting of the protection switch Before using the machine check the ON warning lamp lighting USE AS TROUBLE INDICATOR Placed on the front panel the insulation monitor A3 is a relay which controls continuously the insulation of the generation a c circuits towards the ground The device generates internally a continuous 12V voltage which is applied between the circuit under control and the ground USE AS TROUBLE INTERVENTION The insulation monitor controls a device release coil contactor etc which opens the whole circuit lifting voltage in the whole part of the machine a c generation INDICATOR AND USE OF RI R22M MODEL
3. 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 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 yo
4. UO 60100 18 1v3dl INTO OIGOMAVNV Idde edid au ess aungas Buipe uu au eJojeq NVILHOdINI 1 0 03 04 MOSA MOSA 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 E A S opace 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 warn
5. Y 2 gt cc MOSA MOSA 79 178 90 11 61 ens 22195 122 o 2 Ip uoo ouB sip ajuasaid jap 9 4044 ip e ejes IS WSOIN 21 N 99e10de XsdSiL 39 F yr esour MWWJ dnu eutuoew 5 5 o ATYLI IN ODVSNI 0600Z 210 2uBas 21199211 Bed yy any 1ejsueJ gt uv uoneuiuouaq n WOI panoJdd EJE AE mam E 13N4 1VNOILdO 453 E 2002 01 62 S9L SLL S8 39 uoo e eduuod ELIS Ip V _ TN eooccove LIM TINI AVM 1VNOlILdO V 3LNVANIAVI Ola VO LIM 1VNOILdO 2 ONAld ia Aldana ES OddOUL OLONA T Inqueo JIM GE 85 115 SKID PSX 5 TOYLNO9 79054 YIHSNYYL WOLNV OSVAVYL 2 LAdLNO VdWOd VLIOSN JAH3S3H 104 13441 OSS3HSNI gt zo LL ICO oz 5 2 iagram OVAO C VdlNOd 3NOIZVLN3IATTV OSSIYDNI y IVANVIA JIVANVIA 113 3 4393 VAHASIY OLLWWOLAY QY oouvWolnv IC NO NN NO og Lg os bv be O
6. 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 VOAOORI 30 00 00 M45GB 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 of 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
7. ON VN OISINVOS NI Y S r LLLSSHOIN VN V 31VNVO 2 1 LLLS3SHOIN 19216921078 391009 VIHONWAN V 87184 ddl ULS WHO Wu 31VNVO TAN 3HIH3SNI Id 3NOIZISOd VTINS 444554 HOLIMSdlG I ILLAL J3YOLIA391Y OI99VLI3S e E VN O TINVHO 4 9 SLOYLNOO 39NVHOX3 NI T3NVHO S r SLOVINOI C VN V 13NVHO Z 1 SLOVLNOO a vh EL ZL LL OL 191691048 5 3009 ddl1S LH3SNI NOILISOd NO LAS 38 SIHILIMSdAIA TV Y3A13938 3H1 SNILL3S o 2 WNNALNV p1 l LLL3SHOMW SSH 0 03 06 CF Schema electr MOSA MOSA CD Es spare PARTS LIST MOSA 10 0300 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 iS 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 ESE Europa 59 20090 CUSAGO MI ITALY 2 2 3942 90352 1 fax 39 02 90390466 1 serial number t ssszeszse 2 model of welder and or generating set 3 n table 4 n position 5 quantity Y SJ O A TAVOLA RICAMBI SPARE PARTS PIECES DE RECHANGE ER
8. PSX PMSX MOSA REv 1 09 09 CF The generating set GE 85 115 is a unit which transforms the mechanical energy generated by endothermic engine into electric energy through an alternator 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 GE 85 SKID PSX PMSX GE 115 SKID PSX PMSX GENERATOR Power three phase stand by 88 400 V 127 A 110kVA 400 V 159 A Power three phase PR P 80 400V 115 A 100 kVA 400 144 A Active power stand by 70 4 kW 400 V 88 kW 400 V Active power PR P 64 kW 400 V 80 kW 400 V Frequency 90 Hz 50 Hz Cos 0 8 0 8 ALTERNATOR Type synchronous three phase self excited self regulated Insulation class H ENGINE Make Model PERKINS 11046 44TAG1 PERKINS 11046 44TAG2 Type Cooling system Diesel 4 Stroke Liquid Diesel 4 Stroke Liquid Cylinders Displacement 4 4400 cm 4 4400 cm Power stand by PR P 8 4 kW 106 6 HP 71 3 kW 97 HP 98 kW 133 3 HP 89 kW 121 HP Speed 1500 rpm 1500 rpm Fuel consumption 75 to PR P 14 3 I h 17 1 I h Cooling system capacity 13 13 Engine oil capaci
9. 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 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 EI 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 50 60 Hz switch Cold start advance with temp switch START STOP switch Polarity inverter two way switch Engine protection EP7 A
10. Designer Date Dwg n Approved htip www mosait gt 165 PSX 16 10 2006 84116 S 025 La MOSA si riserva a termini di legge la proprieta del presente disegno con divieto di o comunicarlo a terzi senza sua autorizzazione 13 11 06 84116 560 90 60 20 euoIzezziojne ens 22195 219 e o ojnpoudi ID uoo oufesip eyueseud jap eyeudoud e ip e IS WSOIN 21 ZS0 S 9 0F9 2002 LL SL aoejoda7 XSd SOL E esourwww dilu QU Bed ely Jeufiseq aulyeyy AWLI IIN OOYSNI 06007 aojeubasiq _8 6 998 6 uonoeuuoo JOAO 104 e0913 gt aujo ueDeg 3091014 abe Up onefoJd euorzeuiuoue Bey eq 9jeq dd y ejeg ds GE 85 115 PSX PMSX GE 35 PS PSX Ea e D lt b aq gt KS pd Y o 53 p 2 a E e Y gt gt LLI OC ico iagram VNNALNV ic d CD Schema elettr Electr 3HO LIA3OIMH MOSA MOSA 560 90 60 20 eUOIZezziJone ens 22195 1219 e o OJINPOAAL OJ IAID uoo ouBesip eyueseJd
11. eyaldoud BB p e IS VSOIN 27 Cie 060 S 9 0r9 2002 LL SL XSd p E esourwww dilu OL Beg elly s0u iseg euluoew ATYLI IN 5 06002 0jeAoJddy eJojeubasiq BUIYOOE A 6 6 4 8 dn jag gt 0 ES UJo 199014 ubeg euoizeuiuoue Bed eq Ta ds3 NOILISOd AHL NO LSNW LINN NI HOLIMSdId NO LAS 38 LSNIN MOM LINA vL AHL NI SIHOLIMSdIO TIY H3LLLINSNV IL 9NILL3S gt lt gt lt a GINONAY 38 1 318v9 MOVIE JHL 440 Z WT 440 L oN Tr es 5 GE 35 PS PSX OLTOL 393883 3A30 0TTIIILNOd 11 440 Z 3dO L oN YALLINSNVYL 3NOIZISOd VTINS 393883 Z HILIMSAIO 1 dere vet NO Id 3NOIZISOd TINAS 349559 t V HOLIMSdIG I qHOLllLI3NASVHI OISOVLLAS Ea E e e lt b aq gt MU 5 eem e pl Y TVIH3V SLOVINOI ZL LL 0L SLOVINOI YN 13NVHO 6 8 SLOVINOI NOIZVLN3INITV 01 11 01 LLLSSHOIN VN 31VNVO 6 8 ILLASHOIN VN 31IVNVO 7 9 LLL3SHOIN
12. 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 MOSA M 1 01 M 1 1 M 1 4 M 1 5 2 M 2 5 M 2 6 M 2 7 M3 M 4 2 M 20 M 21 M 30 M 31 M 37 M 38 6 M 39 10 M 39 11 M 39 12 M 40 2 M 43 M 45 M 46 M 60 M 61 R 1 JI O A INDEX REV 0 11 06 CF COPYRIGHT NOTES NOTES TECHNICAL DATA SYMBOLS AND SAFETY PRECAUTIONS ADVICEM 2 6INSTALLATION AND ADVICE INSTALLATIONS AND ADVICE INSTALLATION UNPACKING TRANSPORT AND DISPLACEMENTS SET UP FOR OPERATION START AND STOP CONTROLS LEGEND CONTROLS USING THE GENERATOR TCM 35 REMOTE CONTROL INSULATION MONITORING PROTECTION EARTH LEAKAGE RELAY EP6 ENGINE PROTECTION TROUBLE SHOOTING MAINTENANCE OF THE MACHINE STORAGE CUST OFF ELECTRICAL SYSTEM LEGEND ELECTRICAL SYSTEM SPARE PARTS LIST SPARE PARTS GE 85 115 SKID PSX PMSX 13 11 06 84116 GB MOSA 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 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 CE We advise you to pay atten
13. 05 M39GB OSA MOSA 1 0 10 05 Display 0 P 1 P 2 P 3 P 4 P 5 P 6 P 7 P 8 P 9 P 10 P 11 P 12 OFF P 13 P 14 P 15 PROTECTIONS EP6 ENGINE PROTECTION Parameter Default Remote Start Delay Timing Input 7 1 Range 1 59 secs or 1 15 mins Seconds or minutes of continuous REMOTE START command to initiate the automatic engine start see section 7 0 and 20 in this section Remote Stop Delay Timing Input 7 1 Range 1 59 secs or 1 15 mins Seconds or minutes of continuous absence of the REMOTE START command to initiate the stop cycle see section 7 0 and P 20 in this section Crank Timing Output 10 5 Range 1 20 seconds Maximum insertion time of the Starter Motor Engine Running Trigger 1 8 0 Range 3V 24V inh If the voltage of the Charger Alternator rises above the setting the Starter Motor is disconnected Rest Timing 3 Range 3 20 secs Time interval between starting attempts Starting Attempts 3 Range 1 10 This parameter sets the number of attempts in the automatic start cycle Generator UnderVoltage short circuit inh Range 80 400V If the voltage drops under the setting for at least 6 secs or under setting 20 for 1 sec the Under Voltage protection Lo U will shut down the engine Generator Over Voltage 500V Range 110 550V or inh If the Generator voltage rises abov
14. 24V WARNING LIGHT HOLDER TCM CABLE KIT COMPLETE TCM35 16 06 03 KD
15. 3046 1 Norms and their definitions are listed in the manual s TECHNICAL SPECIFICATIONS page c During the use of the electricity generating group NEVER EXCEED the power indications paying careful attention when several loads are powered simultaneously VOLTAGE GENERATORS WITH COMPOUND SETTING In these types of generators the no load voltage is generally greater than 3 5 with respect to its nominal value f e for nominal voltage threephase 400Vac or singlephase 230Vac the no load voltage can be comprised between 410 420V threephase and 235 245V singlephase The precision of the load voltage is maintained within 5 with balanced loads and with a rotation speed variation of 4 Particularly with resistive loads cos 1 a voltage over elevation occurs which with the machine cold and at full load can even attain 10 a value which in any case is halved after the first 10 15 minutes of operation The insertion and release of the full load under constant rotation speed provokes a transitory voltage variation that is less than 10 the voltage returns to its nominal value within O 1 seconds GENERATORS WITH ELECTRONIC SETTING A V R In these types of generators the voltage precision is maintained within 1 5 with speed variations comprised from 10 to 30 and with balanced loads The voltage is the same both with no load and with load the insertion and release of the full load provokes a transitory volta
16. Check electrical connections and tighten 2 lrregular rotation of motor 2 Ask for intervention of Service 5 Department 9 3 Alternator defective 3 Check winding diodes etc on alternator Refer to alternator manual Repair or replace e Ask for intervention of Service Department 8 e Have qualified maintenance and troubleshooting work e 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 Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete MOVING Use suitable tools and clothes PARTS can injure See pag M1 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 par
17. LAV O C Schema elettr Electr AlddNs sb r e 9 a B o c gt gt iu MOSA 8 GE 85 115 SKID PSX 0 iagram ic d C Schema elettr Electr MOSA MOSA o e gt 1 4 E e 9 lt b aq e co gt LLI 79 178 90 11 61 SUOIZeZZ1JOME ens 22195 1219 e o Jjeoiunuioo o ID uoo OUBasip ayuasaud jap ejeudoud BB Ip 101119 e IS VSOIN 21 Y V 020 S 9LLV9 9002 0L vZ e e1ode XSd SIL 39 F Y esou www dnu A Jeufiseq euue OOWSND 0600Z ojenoJddy aloeubasig 8 2 Bed y IN 11062 1009 xnv gt Vy 0 ES 19 99 S318VO YININISL GNVH pelo ae LOSNNOD UNIT SAOWSY Wed euoizeuiuoueg ed ed i OYLAINOIZNILOd 130 29 99 TENE NE 3HV931109 3 38311901 W TN 4002 OL SL 68 39 uoo e go ezuajod y 91139 VOOL L jn 9839 vaz Vc OMA gt LIM HO4 NINO 2 Les 7 7 7 ji NOLLO313S 4 deg MOLVOIONI NOILO313S 1 dNI HAV 79178 90 11 61 QUOIZEZZIJO NE
18. Overload 1 Check the load connected and diminish 2 Insufficient ventilation 2 Check the cooling vent and relative transmission belts 3 Insufficient coolant liquid Only for 3 Restore level Check for leaks or water cooled motors breakage in the entire cooling circuit pipes couplings etc 28 01 03 401 1500G GE CD GB 68 Troubleshooting GE REV 3 07 06 CF Diesel engine Problem Possible cause Solution 4 Water radiator or oil clogged where it 4 Clean cooling fins on radiator is assembled 5 Water circulating pump defective Only 5 Ask for intervention of Service for water cooled motors Department 6 Injectors defective Injection pump 6 Ask for intervention of Service requires calibration Department 7 Alarm malfunction 7 Check the sensor and electrical circuit GENERATOR Absence of output voltage 1 Voltage switch in position O 1 Check position 2 Voltage switch faulty 2 Check connections and working of the switch repair or replace 3 Protection tripped due to overload 3 Check the load connected and diminish 4 Differential protection device tripped 4 Check on the entire installation Differential switch differential relay cables connections utilities connected have no defective sheathing which may cause incorrect currents to ground 5 Protection devices defective 5 Replace 6 Alternator not sparked 6 Carry out external spark test as indicated in alternator manual Ask for int
19. PLATE EAS SOCKET CUSTODIA PER PRESA EAS BOX EAS SOCKET AVVISATORE ACUSTICO ACOUSTIC ALARM SYSTEM PULSANTE STOP D EMERGENZA EMERGENCY PUSH BUTTON STOP PIASTRA DI CHIUSURA PLATE LOCKSOCKET CONTATTO NC AGGIUNTIVO PER PULSANTE SUPPLEMENTARY CONTACT FOR PUSH KNOB CORNICE FISSAGGIO PANNELLO IN GOMMA RUBBER FIXING FRAME PANNELLO IN GOMMA RUBBER COVER TRASFORMATORE AMPEROMETRICO AMOEROMETRIC TRANSFORMER RELE 12V 70A RELAY 12V 70A PIASTRA APPARECCHIATURE ELETTRICHE PLATE ELECTRICAL EQUIPMENT COPERCH CHIUS FORO SCALDIGLIA COVER PANNELLO FRONTALE FRONT PANEL GUARNIZIONE L MT 1 PROTECTION GASKET L MT 1 qm GUIDA PER MORSETTIERA TERMINAL GUIDE SERRATURA PER COPERCHIO FRONT FRONT COVER LOCK COMMUTATORE COMMUTATOR GUARNIZIONE GASKET qm PIASTRINA PLATE PORTAFUSIBILE HOLDER FUSE STAFFA SUPPORTO INTERR MAGNETOT BRACKET MAGNETO SWITCH INTERRUTTORE MAGNETOTERMICO CIRCUIT BREAKER RELE AVV ELETTRICO RELAY ELECTRIC START GUARNIZIONE GASKET SCATOLA ELETTRICA ELECTRIC BOX CUSTODIA FISSA CONNETTORE CONNECTOR HOUSING FRUTTO PRESA CONNETTORE SOCKET EAS PRESA SOCKET PRESA CEE 400V 125A 3P N T EEC SOCKET PRESA CEE 63A 400V 3P N T EEC SOCKET PRESA CEE 16A 400V 3P N T EEC SOCKET PRESA CEE 380V TRIFASE EEC SOCKET THREE PHASE 380V PRESA 220V 16A EEC SOCKET DISGIUNTORE TERMICO 15A 250V THERMAL SWITCH 15A 250V PANNELLO PORTA PRESE SOCKETS HOLDER FRONT PANEL PRE
20. To vary the regulation call our Technical Assistance Department The LED ON shows that the device is fed Check that it works correctly pressing the TEST push button The LED TRIP will simulate on intervention or anyway will show the real intervention in case the insulation fails Resetthe circuit pressing the RESET push button after having checked the plant and removed the problem cause QQ 25 100 ON TRIP k ohm TEST LEGEND A3 1 Adjustment potentiometer insulation resistance A3 2 Manual reset push button A3 3 Test push button A3 4 Auxiliary fedding presence LED A3 5 TRIP LED INSULATION MONITORING USE OF SRI D3 MODEL To vary the regulation call our Technical Assistance Department The warning light ON shows that the device is fed Pressing a long time the Test push button the Fault led lights and the Alarm led twinkles Leaving it the Alarm led goes off while the Fault led remains lit The pressure on the Reset key brings the device back to initial conditions If the insulation resistance goes down below the fixed alarm value the Alarm led twinkles at the same time the Alarm contact switches if the insulation resistance goes down furtherly and becomes inferior to the fixed value for the Fault the Fault led lights and at the same time both exchange contacts switch putting the Fault in activity and t
21. cycle includes starting trials When the engine starts the led AUTO remains lit continuously and simultaneously the red warning light will light in the TCM35 Stop itis COMPULSORY to disconnect the load first then shift the switch of the TCM35 on 0 the engine will stop immediately 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 For safety reason the key must be kept by qualified personel 02 02 06 84210 GB g89 6ZIN 70 20 80 Jods ay ees eui seu ay Jan y Dc pisinO SA AU 18 lt S 0 6462 cm SUIYDEW ay JO 2 aa J CA ey uo peni si ees 1 ___ _ _ _ _______________________ YUL ay J unjal pue yue apisino ue uJnj9J u JO uonoeuuoo l n y edid eu Jo uonoeuuoo JeSys 10 syeous Jajsues uoljo uuoo z 169 5 2 yue apisino ue ay 40 uonoeuuoo 02 8 Buy edig E e E c c L e c o CD maJys
22. dispositions in force in the place i 69 O6 30 03 00 M45GB MOSA MOSA REV 0 11 06 138 5 Ci Dimensioni Dimensions CF Dimensions CD Ahmessungen Dimensiones ND 2200 1979 125 GE 85 115 PSX PMSX 13 11 06 84116 Dimensioni Abmessungen MOSA Dimensions Dimensiones GE 85 115 SKID REv 0 11 06 Dimensions ND 1120 a J P LL fe NE LL 1 0 d Va 7 Im gt 11 m S__ I AL E AAA s pei dcm CL F 016 n 4 fori 1100 13 11 06 84116 MOSA Ci Dimensioni Dimensions CD Abmessungen Dimensiones GE 85 115 PSX PMSX MOSA REV 0 06 08 Dimensions QD 1200 n 11 A 13 11 06 84116 MOSA lt x N lt lt TANDO o CD CISA GS ELECTRICAL SYSTEM LEGENDE REV 7 10 09 CF Alternator Wire connection unit Capacitor El 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 Arc striking resistor Arc striking circuit 1
23. ens 22095 1219 e OJIBIJNUNUIOI o ip uoo ouB sip jap 9663 e IS VSON 21 panouddy Jeufiseq euen sfedol ODVSNI 0600Z Ded ojeAoJddy eJojeuDesi N0 z 1007 ny Vy 0 W ZE LE N SITAVO LO3NNOO m uogeuuuoueq ANI oll Ge LE oN IAVO SHVO3STIOO UOHEOIIDON jo 1291044 ubed uolzeuluuou Bed eq ded 3 3NOIONV3V OTI3OILLNOd 34311901 GE 85 115 PMSX 4141 09 b ol h o 839 821 al I 1 11 28 E Y lo 5 x LL gt Iz O ni i 5 0 915 9 gt 2 0 Lk ul LIM HI LINOSI YO LIM AVTIH T3 9 404 AINO ico iagram ic d CI Schema elettr Electr IVNOIL LdO Y Et Edid O Y E e Y gt LU MOSA MOSA I 9L 178 90 LL EL QUOIZEZZIJO NE ens 22095 1219 e o jeoiunuioo o Ip uoo ouB sip eyueseJd jap eyeidoud p e IS YSON 1 00 V LCO S OLLES 9002 019 N e2e0de1 XSd G91 _ wesouwwr duu peroJddy n Bq 160 4940 590 9 98 5 4 0 A
24. 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 E Vie Europa 59 20090 CUSAGO MI ITALY o 1 0 CS AN tel 39 02903521 fax 39 0290390466 Vle Europa 59 20090 CUSAGO MI ITALY http www mosa it e mai infoemosa it 38 02903521 fax 39 0290390466 tel 48 in VESTALY TYPE http www mosait e mail infoemosa it i N O O O i IN Uo Hz 1 9 5 Eme TTA 41 11 _ IRM RPM PC ____ __ ____ 100 Furthermore on each model it is shown the noise level value the symbol used is the following yy db 10 10 02 1 4 GB The indication is shown in clear readable indeleble sticker s D Es A TECHNICAL DATA GE 85 115 SKID
25. reset 2 Regulation of intervention time 0 5 seconds 3 Regulation of fault current 30 mA 4 Output relay N De or N E according to the model of the machine c In order to modify the set up call the Technical Assistance Centres The GFI is equipped with three tests two of which effected automatically by the instrument 1 manual test trial push button 2 automatic test of the toroid relay connection guard 3 automatic test of the board electronics In case of fault the output relay trips and the Fault led lights with fixed light It is able to work correctly even in presence of harmonic distortion or anyway with very disturbed signals In case the internal temperature goes over the threshold for a good functioning the Fault led will twinkle Its interruption due to a fault of the toroid break of the connection wire or a fault in the internal circuits brings to the automatic intervention of the protection To help the user in setting up the intervention delay the potentiometer t s rotation in correspondence of a reference mark causes the Fault led to twinkle for a few seconds EARTH LEAKAGE RELAY LEGEND D1 Potentiometer for earthing fault current regulation D2 Potentiometer for intervention time regulation D3 Multifunction led for indication of internal electronics fault internal temperature out of range t s centred correctly Led indicating presence of feeding Led indicating intervention of GFI
26. 10V D C 48V D C diode bridge E P 1 engine protection Engine stop solenoid Acceleration solenoid Fuel level transmitter Oil or water thermostat 48V D C socket Oil pressure switch Fuel warning light Battery charge warning light Oil pressure warning light Fuse Starter key Starter motor Battery Battery charge alternator Battery charge voltage regulator Solenoid valve control PCBT Solenoid valve Remote control switch Remote control and or wire feeder socket Remote control plug Remote control welding regulator E P 2 engine protection Fuel level gauge Ammeter Frequency meter Battery charge trasformer Battery charge PCB Voltage selector switch 48V a c socket Thermal relay Contactor G EI and circuit breaker 42V EEC socket G FI resistor TE P engine protection Solenoid control PCBT Oil level transmitter Engine stop push button T C 1 Engine start push buttonT C 1 24V socket Thermal magnetic circuit breaker S C R protection unit Remote control socket Remote control plug 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 Oil shut down button Battery charge diode Relay Resistor Sparkler reactor Output power unit Electric siren E P 4 engine prot
27. 168340 16 841168015 17 309509005 18 841168003 19 841168004 20 841168464 21 841252068 Descr Note GOCCIOLATOIO CARENATURA SUPERIORE COMPL FIANCATA POSTERIORE SINISTRA PARETE SCARICO ARIA MOTORE PIASTRA PARA ACQUA SILENZIATORE DI SCARICO GUARNIZIONE L MT 1 qm PANNELLO INFERIORE PER CASSONETTO SCARICO RACCORDO TUBO SCARICO TUBO SCARICO COLLEGAMENTO MARMITTA GUARNIZIONE GUARNIZIONE SCARICO MOTORE fornita con motore FIANCATA POSTERIORE DESTRA SCARICO CORNICE SUPPORTO CARENATURA FIANCATA CARENATURA DESTRA GUARNIZIONE FIANCATA CARENATURA DESTRA FIANCATA CARENATURA SINISTRA STAFFA FERMO FONO ASSORBENTE FLANGIA PER SCARICO qm Da REV 1 09 09 Del 87 09 15 07 09 Descr Note DRIPPER TOP COVER COMPL REAR LEFT COVER ENGINE AIR EXHAUST SITE WATER BAFFLE BOARD EXHAUST MUFFLER STRIP SEALING L MT 1 LOWER PANEL FOR AIR INLET BOX PIPE FITTING EXHAUST PIPE EXHAUST PIPE FOR MUFFLER GASKET GASKET REAR RIGHT COVER EXHAUST PIPE SUPPORTING FRAME FOR COMPLETE COVER COVER RIGHT SIDE GASKET COVER RIGHT SIDE COVER LEFT SIDE SOUND PROOF MATERIAL BRACKET EXHAUST PIPE FLANGE From REV 1 09 09 Del 87 09 15 07 09 13 11 06 84116 930357219 930359913 930357227 930357231 93035C060 930350000 INTERRUTTORE 2P 16A SCATOLA COMPLETA LAMPADA 24V PORTALAMPADA SPIA ROSSA GR CAVI TCM TCM35 COMPLETO TCM35 930350000 INTERRUPTER 2P 16A CASE COMPL WARNING LIGHT
28. 7 P 28 P 29 CD 1 0 10 05 CF PROTECTIONS EP6 ENGINE PROTECTION Stop Solenoid Timing 2 Range 2 99 secs Duration of the Stop cycle Alarm Output Timing 17 inh 59 secs 1 15 mins and cont Time out of the alarm output The code cont disables the time out and the alarm remains energized until the OFF operating mode is selected The inh mode enables the use of the external contactor Temperature Switch n o Selection n o or n c n o the engine shuts down if the contact closes n c the engine shuts down if the contact opens ALARM Control n c Selection n o or n c n o the engine shuts down if the contact closes n c the engine shuts down if the contact opens Remote Start n o Selection n o or n c n o the engine starts if the contact closes n c the engine starts if the contact opens Under Speed setting Inh Inh or 100 4000 r p m The Inh code disables the Under Speed shut down Over Speed setting Inh 100 4000 rpm or Inh The EP6 provides one second bypass delay The Inh code 24000 r p m disables the Over Speed shut down Number of Teeth of the Flywheel Inh Inh or 1 500 teeth The Inh code disables the reading of the Speed section 3 0 the Over Under Speed alarms and the Crank termination see P 24 Crank OFF Inh Crank Termination setting 100 800 rpm If the speed rises above the setting the EP6 terminates the cr
29. 91mm 0 5 x 91mm 0 5 Front view SIDE VIEW Cables outlet 12 10 05 M39GB CD O CA Troubleshooting GE MOSA _ REV 3 07 06 CE Diesel engine Problem Possible cause Solution The motor does not start 1 Start up switch 16 where it is 1 Check position up assembled in incorrect position 2 Emergency button L5 pressed 2 Unblock 3 Preheating where it is assembled 3 Lacking or insufficient preheating phase for sparkplugs Malfunction in circuit repair 4 Engine control unit or starting key 4 Replace faulty 5 Battery low 5 Recharge or replace Check the battery charge circuit on motor and automatic panel 6 Battery cable terminals loose or Tighten and clean Replace if corroded corroded Q 7 Start up motor defective 7 Repair or replace 8 No fuel or air in feed circuit 8 Refill tank un aerate the circuit 9 Malfunction on feed circuit defective 9 Ask for intervention of Service pump injector blocked etc Department 10 Air filter or fuel filter clogged 10 Clean or replace 11 Air in the gasoil filter 11 Take the air out filling the filter with gasoil 12 Motor stopping device defective 12 Replace 13 Malfunction on electrical power circuit 13 Check and repair on generator control panel The motor does not 1 Al r filter or fuel filter clogged 1 Clean or replace accelerate Inconstant 2 Malfunction on feed circuit defective 2 Ask for intervention of Service speed pump inje
30. ATED BY BCS S p A UNITA OPERATIVE OPERA TAE UNITE Sede e Unit Operativa Viale Mazzini 161 20081 Abbiategrasso MI Unit Operative Via Valbrina 17 18 42045 Luzzara Europa 59 20080 Cusago MIT haha E CONFORME ALLA HORMA 5 IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2000 PER LE BEGUENMTI ATTIVITA FOR THE FOLLOWING ACTIVITIES EA 18 Progettazione produzione ed assistenza di tratton macchine per agricoltura e manutenzione del verde motosaldalnc e gruppi elettrogeni Design production and servicing of tractors agricultura and green maintenance machines engine divan welders and generating sels erri 8 Marsa dela Quant pe api abi des agunt dla orca 1550 OX LADDER Lr rp E m ul pet Ac e DE arua de tries di pavone pavia posta dele chi Far memet 8 Ho Dente plene Depa al re ilem 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 Information and 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
31. GE 85 SKID PSX PMSX GE 115 SKID PSX PMSX 641169003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOGS 13 11 06 84116M00 preparato da UPT approvato da DITE MOS GS DESCRIPTION oF THE MACHINE GE 85 115 SKID PSX PMSX MOSA REV 1 09 09 CF Main Characteristics of GE 85 Main Characteristics of GE 115 Three phase electric power max 88 kW 400 V 50 Hz Three phase electric power max 110 kW 400 50 Hz e Perkins Diesel engine 1104C 44TAG1 Perkins Diesel engine 1104C 44TAG2 e Synchronous alternator Synchronous alternator Tank of 2301 with autonomy of 16h Tank of 2301 with autonomy of 14h Dimensions weight 2740 2000 skid x1200x1640 Dimensions weight 2740 2000 skid x1200x1640 1425 Kg SKID 1655 Kg PSX 1620 Kg PMSX 1450 Kg SKID 1680 Kg PSX 1665 Kg PMSX Noise level at 7m 70dB A Noise level at 7m 71dB A Prepared for automatic start unit Prepared for automatic start unit e Prepared for remote start stop Prepared for remote start stop FILTER CONNECTOR FOR EAS OR REMOTE START MUFFLER EMERGENCY STOP The unit is composed by a tank an engine alternator unit fixed on the base by 4 elastic dampers a roll bar with hook for an easy and sure lifting a base complete with doors for a quick access to the engine to the air filter and to the battery The set is also equipped with a electrical board where there are mounted protect
32. In case of alarm consult your Generating Set manufacturer To remove the message turn OFF the KEY SWITCH The EP6 may show one of the following O SPd Over Speed of the engine U SPd Under Speed ofthe engine _ Fuel in d OSA MOSA FAIL 3 Starting Failure Alarm E 05 2 Generator Overload Hi H 2 Generator Over Frequency Lo H 2 Generator Under Frequency Hi U 2 Lo 012 Battery Voltage der Memoro Eo Amaral 1 FUEL This message indicates Low Fuel in the tank The engine stops if the contacts remain closed for 5 minutes continuously To clear the alarm follow the instructions a turn OFF the key switch b fill the tank C turn ON the key to display the message FULL d turn OFF the key in order to cancel the alarm e turn ON the key to select the MANUAL or AUTO operating mode 2 To determine the value that caused the failure push the F1 pushbutton 4 1 OPERATING messages EP6 features messages to inform you about the following uuuu Glow plugs timing U Voltage out of range StA Start prompt Starting by key switch rESt Rest timing tESt Automatic Test CAL Calibration Pro Programming rEAd Parameter reading StOP Stopping cycle MM SS Remote Start or Remote Stop cycle EP6 ENGINE PROTECTION 5 0 LEDs for visual indication The EP6 features two LEDs see section 10 0 to indicate the following
33. RSETTO FIANCATA INTERMEDIA CASSONETTO ASPIRAZIONE Descr Note GASKET qm GLASS COVER COVER COMMANDS SIDE UP EAVING RING OR RING FLANGE FOR AIR TIGHT SEALED COVER ERMETIC COVER TIEROD DOUBLE RING REAR COVER LATCH ALTERNATOR INSPECTION COVER FRONT COVER PLATE LOCKSOCKET CENTRAL WING DOOR PANELIST FOR SIDE COVER HARMONIC WIRE JACK GEAR LOCK TERMINAL MIDDLE COVER INDUCTION CASE Tabla de recambios GE 85 115 SKID PSX PMSX 13 11 06 84116 Y HL ON gt V 7 1 LX 2 YI 7 9 ZU Tabla de recambios GE 85 115 SKID PSX PMSX Ersatzteile REV 09 09 CEO Pi ces de rechanges D 06 lt MOSA 15 10 11 12 13 14 191198 90 11 61 CD Ricambi Spare parts D Ersatzteile Tabla de recambios GE 85 115 SKID PSX PMSX 1 09 09 de rechanges MOSA MOSA Pos Rev Cod 1 841168068 2 841178091 3 841168025 4 840858215 5 841168075 6 841252050 7 105112270 8 840858168 9 841172078 10 841172081 11 325252069 12 840752069 13 841168020 14 841162070 15 841168340 16 841168015 17 309509005 18 841168003 19 841168004 20 841168464 21 841252068 Pos Rev Cod 1 841168068 2 841178091 3 841168025 4 840858215 5 841168075 6 841252050 7 105112270 8 840858168 9 841172078 10 841172081 11 325252069 12 840752069 13 841168020 14 841162070 15 841
34. SATZTEILE EA 34 4 13 48 18 17 16 20 21 22 o me 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 22 o CS o a Ze LO qe M GO 25 gt e e e D 7 En N L CD Ricambi M O SA Spare parts 1 09 09 de rechanges MOSA 191198 90 LL EL 14 29 26 2 2 W A SA T 3x 2 AA A ES DA N 27 28 19 2 m 43 27 de gt A A cau Y A DD SIA 107 71 44 24 1 o 2 26 N b MUSA OMOSA REV1 09 09 Pos Cod 1 841162200 1 840962200 2 841153100 2 841263100 2 840953100 2 840873100 4 841162228 5 041162352 6 105611550 7 744502032 8 841163101 9 840951262 10 842251262 11 841162020 12 841161296 13 841161050 14 842252026 15 764409975 16 1240060 17 1243020 18 1241010 19 764409150 20 400409154 21 841161061 22 107509905 23 841167102 24 841167004 25 841161100 26 841162212 27 740352211 28 317802310 29 841183101 CD Rica
35. SE SCHUKO SCHUKO SOCKETS 13 11 06 84116 191198 90 11 61 72 D 26 a N ve LO 5 Mm o vc E N Di o 8 6 Y a cs LU 9008 D ___ _____ a E N 8 n 23 02 o a 00 O66 m CC vr El CD Ricambi Spare parts D Ersatzteile REv 0 06 08 CF de rechanges MOSA MOSA Pos Rev Cod 1 309509005 2 841168080 3 841168426 4 6033050 5 1018130 6 841658361 7 841658360 8 841659357 9 841659358 10 841168035 11 744508140 12 841258125 13 841168080 14 741167032 15 841168458 16 841168461 17 842258460 18 842258163 19 105111450 20 841168428 21 841168220 Pos Rev Cod 1 309509005 2 841168080 3 841168426 4 6033050 5 1018130 6 841658361 7 841658360 8 841659357 9 841659358 10 841168035 11 744508140 12 841258125 13 841168080 14 741167032 15 841168458 16 841168461 17 842258460 18 842258163 19 105111450 20 841168428 21 841168220 Descr Note GUARNIZIONE qm SCHERMO PER PORTELLA FIANCATA LATO STRUMENTI GOLFARE ANELLO OR GHIERA PER COPERCHIO ERMETICO COPERCHIO ERMETICO TIRANTE IN GOMMA ANELLO DOPPIO CARENATURA POSTERIORE CERNIERA PER FIANCATA COPERCHIO MANUTENZIONE ALTERNATORE CARENATURA ANTERIORE PIASTRA DI CHIUSURA FIANCATA INTERMEDIA BATTENTE LISTELLO FERMO FIANCATA FILO ARMONICO CHIUSURA A CRICCHETTO MO
36. SUPPORT BRACKET GE 85 115 PMSX Da REV 1 09 09 Del 101 08 08 05 08 13 11 06 84116 Ricambi D Ersatzteile MOSA Spare parts Tabla de recambios GE 85 115 SKID PSX PMSX REV 0 06 08 CF Pi ces de rechanges ND 11 12 13 14 no 13 11 06 84116 MOSA MOSA Pos Rev Cod 1 325507305 2 JK0029770 3 102042740 4 744507057 5 305717315 6 325507027 7 325507210 8 744508103 9 105191560 10 105191570 11 105191550 12 315507215 13 744507219 14 841167032 15 744507237 16 841167074 17 841167075 18 325507306 19 317619199 20 840857009 21 359257032 22 841167020 23 306418310 24 1243020 25 744508112 26 102013290 27 309509005 28 1241010 29 107509045 30 841167036 31 841157325 32 306479199 33 107509005 34 841167010 35 744507170 36 744507171 3 107509903 38 746507270 39 344027270 40 305907270 41 105111510 42 307017240 43 155307107 44 841167065 45 259107241 CD Ricambi Spare parts D Ersatzteile Tabla de recambios GE 85 115 SKID PSX PMSX REv 0 06 08 CF Pi ces de rechanges ND Descr Note AMPEROMETRO AMPEROMETER UNITA CONTR MOTORE EP6 ENGINE UNIT CONTROL EP6 CAPPUCCIO CAP CHIAVE SERRATURA QUADRO ELETT ELECTRICAL BOARD KEY COMMUTATORE COMMUTATOR COPERCHIETTO RELE DIFFERENZ RELAY COVER INDICATORE LIVELLO CARBURANTE FUEL LEVEL GAUGE CERNIERA X COPERCHIO FRONTALE LATCH X FRONT COVER FRUTTO PRESA CONNETTORE SOCKET EAS COPERCHIO PER PRESA EAS BLIND
37. UTOIDLE switch AUTOIDLE PCB A4E2 ECM engine PCB Remote emergency stop connector V A digital instruments and led VRD PCB Water in fuel Battery disconnect switch Inverter Overload led Main IT TN selector NATO socket 12V Diesel pressure switch Remote control PCB Pressure turbo protection 26 07 04 M60GB I 9LL78 90 11 61 euorzezzuojne ens ezues 219 e o o inpoidu uoo ouBesip ejueseuJd eyeudoud ip euiesu IS VSON 87 1 TY OL a9eJoda7 XSd SU 39 lt i esouu www dnu Bed ely ATVLI IW OSVSnO 0600Z 3oeloJd Uip u Bed bed xoe q oeu He v 8 9 2 8 60L VoL 4 GE 85 115 SKID PSX 5 xoe q oJeu 4 aa pee eco AA AA 8 2 Ed 10 110 vC A A A A ME 21 GL LL ID 2 ico iagram ic di 2 E C Schema elettr Electr ES gt r 65 a E 65
38. WLIAIN ODVSNI 0600Z BE 4U SsI i eJojeubasiq EUIUDIE N Bed LIN INEXOEZ SX LOOP SIOADOS xn y gt O ES a Hrs tn 2 O ROSE 1002 01 91 S9L SLL S8 39 LIUN 0 463 lt les GE 85 115 SKID PSX PMSX 9 V9L AO C V9L NOOY VE9 A00p VSCV AO0T ES N 1 1 89914 811 49 SER XT 9839 00 OI 89139 VOSZ 91 39 VOOL 6839 92 RR lt ico iagram ic d C Schema elettr Electr Y a e D c o E e o co e co gt CC MOSA MOSA Schema elettrico M SA Electric diagram GE 85 115 SKID PSX PMSX OMOSA _ 0 11 06 CF Schemas electriques G F l RELAY 121111109 1817 ATTENZIONE Scollegare ponticello per disabilitare G F I ATTENTION To disable G F I disconnect jumper ISOMETER ISOMETER DOSSENA 17 16 15 14113 1211 Esp Modifica Data Dis Appr Exp Modification Date Desi Appr Da i Denominazione Progetto Pag n din 6 From Page Denomination Project ofn M DJ JAN Electrical diagram for G F I Relay or Isometer 84165 prg 7 9 A Alla Macchina Disegnatore Data Dis n Approvato 20090 CUSAGO MI ITALY To Page Machine
39. ank cycle One seconddelay avoids false termination code Inh inhibits the crank termination Low Oil Pressure Alarm By Pass 6 Range 0 99 secs By Pass Delay to ignore the Oil Pressure input 3 during the engine starting cycle This input requires normally closed contact Automatic Periodic Test Cycle inh Range inh 1 99 days This is the interval time between the automatic periodic tests of the engine The code inh disables the Automatic Periodic Test see section 19 0 Automatic Engine Test Duration 5 Range 1 99 minutes This is the duration of the automatic engine test Generator warm up timing 20 Range inh 1 59 secs or 1 15 mins inh No warm up Active only when 17 inh and the ALARM output is used to drive the contactor Generator cooling timing 30 Range inh 1 59 secs or 1 15 mins inh No cooling Active only when P17 inh and the ALARM output is used to drive the GEN SET contactor 12 10 05 M39GB CD PROTECTIONS 1 0 10 05 CF 7 0 REMOTE START The EP6 features REMOTE START only in AUTO operating mode To operate the REMOTE START follow the instructions OSA MOSA A Turn the KEY SWITCH to the ON position the Display and LEDs illuminate for 1 sec B Wait until the end of the LEDs test C Push the AUTO pushbutton as soon as possible otherwise after 20 seconds the EP6 enters the STARTING FAILURE the AUTO yellow LED will illuminate as de
40. conditions ENGINE RUNNING this green led illuminates when the engine is running AUTO this yellow LED blinks to indicate a standby mode The EP6 monitors the REMOTE CONTROL and expects a command The LED illuminates continuously when the REMOTE START Is activated 5 1 LEDs and Display Test A test of the LEDs and DISPLAY is obtained automatically anytime the key switch is turned ON The LEDs and DISPLAY light up for about 1 second 6 0 Parameters and settings The unit is programmed by the supplier of the Generating Set Contact the Generator manufacturer in order to have the permission to program the module It is possible to read the status of the internal programming at anytime Follow the instructions A Turn the Key in OFF if the display indicates STOP wait until it disappears B Push and hold the F1 pushbutton until the message rEAd appears 10 secs C Release the button the display will show the first programmable parameter P 0 D Push the F1 pushbutton the display will indicate the value of the parameter 1 E Push the UP DOWN pushbutton to select a parameter P 0 to P 29 Push F1 to display the setting F The display returns to menu mode if you have not used the pushbuttons for 30 seconds The list of the parameters follows means minutes and means seconds Some parameters may differ according to the programming done by the genset manufacturer 12 10
41. ctor blocked etc Department 3 Oil level too high 3 Eliminate excess oil 4 Motor speed regulator defective 4 Ask for intervention of Service Department ________________________________________________________________________________________________________________________________________________________________ Black 1 Airfilter clogged 1 Clean or replace 2 Overload 2 Check the load connected and diminish 3 Injectors defective Injection pump 3 Ask for intervention of Service requires calibration Department White smoke 1 Oil level too high 1 Eliminate excess oil 2 Motor cold or in prolonged operation 2 Insertload only with motor sufficiently with little or no load hot 3 Segments and or cylinders worn out 3 Ask for intervention of Service Department E eOOEO Y ryee a oh iii mi A a a a i a Too little power provided 1 Airfilter clogged 1 Clean or replace by motor 2 Insufficient fuel distribution impurities 2 Check the feed circuit clean and or water in feed circuit refill once again 3 Injectors dirty or defective 3 Ask for intervention of Service Department E e Low oil pressure 1 Oil level insufficient 1 Reset level Check for leaks 2 Airfilter clogged 2 Replace filter 3 Oil pump defective 3 Ask for intervention of Service Department 4 Alarm malfunction 4 Check the sensor and electrical circuit High temperature 1
42. 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 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
43. cy Inhalation In case of exposure to high concentration 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 death follow the first aid as described by the ruling norms local ones EXTINCTION MEANS Appropriated arbonate anhydride or carbon dioxyde powder foam nebulized water otto 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 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 M2 51 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 buildi
44. d coolant follow the operations described in the motor operating manual 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 regulations in force for electrical installations and safety TS DSP Water cooled systems 12 06 03 M20 R HO2 GB GE 14000 YS GS GE 20 35 55 65 PS PSX GE 85 115 145 165 3 Start with Automatic start unit EAS Put the Local Remote selector on Remote Connect the EAS to unit The EAS controls the starting as well as the stop of the engine Follow attentively the instructions reported in the EAS manual In these conditions the EP6 has the only function to measure the electric values hour meter etc wis MOS cs START AND STOP MOSA REV 0 02 06 Check daily Do not alter the primary conditions of regulation and do not touch the sealed parts The starting of the unit can be ef
45. e coil Engine control unit EP6 Welding voltage voltmeter Polarity inverter control Oil pressure indicator Remote control switch Selection push button 30 I 1 PTO HI Battery voltmeter Remote control socket Button indicating light 20 11 PTO HI Commutator switch serial parallel Thermal magnetic circuit breaker Selection push button 20 I 1 PTO HI Water temperature indicator 10 05 01 M30 GB T Gomantdi D MOSA o contos C Mandos GE 85 115 SKID PSX PMSX OMOSA _ REV 0 11 06 Commandes QD 72 6 VERSIONE STANDARD 6 SOCKETS KIT SR STANDARD VERSION SR B3 13 11 06 84116 CD CA Using the generator 1 1 09 05 CE It is absolutely forbidden to connect the unit to the public mains and or another electrical power source Access forbidden to area adjacent to electricity generating group for all non authorized personnel The electricity generating groups are to be considered electrical energy producing stations The dangers of electrical energy must be considered together with those related to the presence of chemical substances fuels oils etc rotating parts and waste products fumes discharge gases heat etc GENERATION IN AC ALTERNATING CURRENT Before each work session check the efficiency of the ground connection for the electricity generating group if the distribution system adopted requires it such as for
46. e the setting for at least 2 seconds the EP6 will energize the over voltage protection Hi U see section 4 0 to stop the engine The inh code inhibits the over voltage Generator Under Frequency Inh inh 1 to 99Hz inh disables the under frequency This protection is delayed by about 6 seconds The EP6 shuts down the engine and the display will show the Lo H message Generator Over Frequency 55 45 Hz to inh inh disables the over frequency This protection is delayed by about 2 seconds The EP6 shuts down the engine and displays Hi H Current Transformer Size The range is 10 5 up to 1000 5 Generator Overload Setting inh Range inh to 1000 AThe EP6 shuts down the engine after a delay of 6 secs and shows the message E05 Generator Failure Alarm selection on or OFF The code on enables the Generatorfailure alarm The EP6 shows the E04 message and the engine will shut down Glow Plugs Choke Control Output 11 5 Range 1 to 99 secs The EP6 energizes the output 11 for the programmed time Output Control 0 The following options are available 0 None 1 Choke Control 2 Glow Plugs Control 3 Choke Control Belt Break Control ON Selection on or OFF The Belt Break alarm is indicated by means of the message bEL t 12 10 05 M39GB OSA MOSA P 16 P 17 P 18 P 19 P 20 P 21 P 22 P 23 P 24 P 25 P 26 P 2
47. ection Engine control R P M electronic regulator PTO HI control PCB PTO HI 20 l min push button PTO 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 thermostat 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 5 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
48. ed as generator group and or welder otop engine when 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 p arts on the circuit Do not fill tank completely Wipe up spilled fuel before starting engine had hut off fuel of tank when moving machine where it is assembled An electric shock can kill Avoid spilling fuel on hot engine oparks may cause the explosion of battery vapours Www IS 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 do to the hospital with the utmost urgen
49. ed periods of inactivity MAINTENANCE GENERATING SET WITH AUTOMATIC BOARD EVERY MONTH AND OR AFTER INTERVENTION ON 1 TEST or AUTOMATIC TEST cycle to keep the generating set constantly operative 2 Check all levels engine oil fuel level battery electrolyte if necessary top it up 3 Control of electrical connections and cleaning of control panel gt Carry out motor oil change at least once a year even if the requested number of hours has not been attained 05 09 05 M43GB CD STORAGE 1 0 06 00 CEO 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 gt 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 In 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
50. erating mode B if the KEY SWITCH is in the ON position the EP6 enters the AUTO operating mode That is if the EP6 was in AUTO prior to the supply removal If not the EP6 enters the MANUAL operating mode 2 1 AUTO operating mode To enter the AUTO operating mode use the following instructions A Turn ON the key switch the Display and LEDs illuminate for 1 second B Wait for the end of the LAMP test then push the AUTO pushbutton after the UUUU Pre glow or Sta Start prompt has been displayed After this the yellow Led AUTO will illuminate If the REMOTE START input is not operative the LED will flash If operative the LED illuminates continuously and a start cycle will take place NOTE the EP6 shuts down the display during the crank C In order to cancel the AUTO operating mode EP6 ENGINE PROTECTION push the AUTO pushbutton the yellow Led will turn OFF or turn the KEY SWITCH to OFF Once in AUTO the EP6 waits for a REMOTE START activation see section 7 0 In case of an Automatic Periodic Test A P T the display will show the message tESt 2 2 MANUAL operating mode To start the engine follow the instructions A Turn ON the KEY SWITCH the EP6 illuminates the LEDs and Display B If the display shows the message uuuu the EP6 is counting the PRE GLOW time wait until the message disappears C After the display shows the flashing message StA NOTE turn the Key to START po
51. ervention GE _ Diesel engine USAGE WITH EAS AUTOMATIC START UP PANEL The electricity generating group in combination with the EAS automatic start up panel forms a unit for distributing electrical energy within a few seconds of a power failure from the commercial electrical power line Below is some general operating information refer to the automatic panel s specific manual for details on installation command control and signalling operations L Perform connections on the installation in safety conditions Position the automatic panel in RESET or LOCKED mode Carry out the first start up in MANUAL mode Check that the generators LOCAL START REMOTE START switch 16 is REMOTE position Check that the generator switches are enabled input lever in upward position Position the EAS panel in manual mode by pressing MAN key and only after having checked that there are no dangerous situations press the START key to start the electricity generating group During the operation of the generator all controls and signals from both the automatic panel and group are enabled it is therefore possible to control its operation from both positions In case of an alarm with a shutdown of the motor low pressure high temperature etc the automatic panel will indicate the malfunction that has caused the stoppage while the generator s front panel will be disabled and will no longer supply any information
52. ervention of Service Department 7 Alternator defective 7 Check winding diodes etc on alternator Refer to alternator manual Repair or replace Ask for intervention of Service Department p 3 No load voltage toolowor 1 Incorrect motor running speed 1 Regulate speed to its nominal no too high load value 2 Voltage regulating device where itis 2 Adjust regulator device as indicated assembled defective or requires in alternator manual or replace calibration 3 Alternator defective 3 Check winding diodes etc on alternator Refer to alternator manual Repair or replace Ask for intervention of Service Department C A AAAAAAA LAL AA A AAA A AAA AAA AAA AA AA LA A AA A A A A ff _ Corrected no load voltage 1 Incorrect motor running speed dueto 1 Check the load connected and too low with load overload diminish 2 Load with cos less than 0 8 2 Reduce or rephase load 3 Alternator defective 3 Check winding diodes etc on alternator Refer to alternator manual Repair or replace Ask for intervention of Service Department J CC A A Unstable tension 1 Contacts malfunctioning 1
53. est we recommend the following procedures disconnect the power supply of the EP6 consult your genset supplier wait for the desired start time external clock reference apply the power supply to the EP6 consult your genset supplier select the AUTO operating mode The EP6 will start the engine after the programmed number of days and the engine will run for the programmed time To determine how the Automatic Periodic Test is programmed enter the Reading Mode section 6 0 parameter P 26 and P 27 IMPORTANT NOTES If the supply battery voltage is removed the EP6 loses the counts and timings If the supply restores the EP6 starts to count the A P T according to the programmed parameters P 26 and P 27 It is important to synchronize the power on sequence with the desired Automatic Periodic Test 10 0 FRONT PANEL 4 digits DISPLAY UP DOWN Engine Control Button Ideograms iL FuEL F RPM Green LED e b ui engine on SUELE hi hours Button Button F1 AUTO AUTO Yellow Button Led ENTER Button Ke Button y OFF ON START The use of these buttons is reserved only to the manufacturer of the generating set 11 0 DIMENSIONS Tam 30mm 45mm HU FUEL E Sc Sea bia ON n Y vd i Rear cove Closing cover Rear view Recommended hole dimensions
54. example the TT and TN systems Check that the electrical specifications for the units to be powered voltage power frequency are compatible with those of the generator Values that are too high or too low for voltage and frequency can damage electrical equipment irreparably In some cases for the powering of three phase loads it is necessary to ensure that the cyclic direction of the phases corresponds to the installation s requirements Connect the electric devices to be powered to the AC sockets using suitable plugs and cables in prime condition Before starting up the group make certain no dangerous situations exist on the installation to be powered Check that the thermal magnetic switch Z2 is in the OFF position input lever in downward position Start up the electricity generating group positioning the thermal magnetic switch Z2 and differential switch D to ON input lever in upward position Before powering on the utilities check that the voltmeter N and frequency meter E2 indicate nominal values in addition check on the voltmeter change over switch H2 where it is assembled that the three line voltages are the same s the absence of a load the values for voltage and frequency can be greater than their nominal values See sections on VOLTAGE and FREQUENCY OPERATING CONDITIONS Diesel engine There are various types of power PRIME POWER PRP STAND BY POWER established by ISO 8528 1 and
55. fected in 3 different modes 1 Start with EP6 key Engine Control Put the Local Remote selector on Local Turn the key on ON the EP6 display shows only on the machines with mounted glow plugs for 5 secs the symbol UUUU then the message Sta appears the engine can be started for which turn the key on start and start the engine On the display the word Sta remains for about 20 secs then automatically disappears the engine must be started within 20 secs otherwise the EP6 blocks the starting and on the display the word fail appears Turning the key on OFF the EP6 is reset and a new starting cycle be fixed Stop itis COMPULSORY to disconnect the load first then to stop the engine turn the key on OFF MACHINE WITH EMERGENCY BUTTON Pressing the button the engine will stop immediately in any working condition 2 Remote starting with TCM35 Put the Local Remote selector on Local Connect TCM35 to the plug on the front panel and put the switch on 0 Turn the key on ON in the EP6 Engine Control wait for the various signals to go out then press the button AUTO in the EP6 until the led AUTO flashes Shift the switch on in the TCM35 and automatically the starting cycle will start On the RUNNING IN During the first 50 hours of operation do not use machines with mounted glow plugs appears in the display EP6 for about 5 secs the symbol the starting
56. ge variation that is less than 15 the voltage returns to its nominal value within 0 2 0 3 seconds FREQUENCY The frequency is a parameter that is directly dependent on the motor s rotation speed Depending on the type of alternator 2 or 4 pole we will have a frequency of 50 60 Hz with a rotation speed of 3000 3600 or 1500 1800 revolutions per minute The frequency and therefore the number of motor revolutions is maintained constant by the motor s speed regulation system Generally this regulator is of a mechanical type and presents a droop from no load to nominal load which is less than 5 96 static or droop while under static conditions precision is maintained within 196 Therefore for generators at 50Hz the no load frequency can be 52 52 5 Hz while for generators at 60Hz the no load 5 frequency can be 62 5 63Hz POWER The electrical power expressed in kVA on an electricity generating group is the available output power to the reference environmental conditions and nominal values for voltage frequency power factors cos o 12 06 03 M37GB_150 a M SA Using the generator MOSA 1 1 09 05 CF In some motors or for special requirements the speed regulator is electronic in these cases precision under static operating conditions attains 0 25 and the frequency is maintained constant in operation from no load to load isochronal operation POWER FACTOR COS 9 The power factor is a
57. he Alarm at rest After having checked the device and removed the cause of the problem re establish the circuit pressing the push button RESET Surveyor SRI D3 TEST Alarm OnWFaut RESET D 4 D6 gt O Qel 07 D 5 Alarm Fault 200 e 80 e D 3 100 3 40 D1 US Nso 1207 lt TD 2 I LEGEND D1 Regulation of Alarm threshold D2 D3 D4 D5 D6 D7 Regulation of Fault threshold Led fault indication Led feeding indication Led Alarm indication Test push button Reset push button 25 05 01 M39GB CD ENGINE PROTECTION USE 1 1 10 05 MOSA MOSA Don not intervene on the setting of the protection switch Before using the machine check the ON warning lamp lighting The relay allows to select the tripping current value so as to keep values of contact voltage of the limits indicated by the electrical security norms These adjustments allow to perform a tripping selecticity or either current or delay when more relays are located along the same line in protection of the different starting signals SW G F l The SW G F I switch placed inside the electric control panel or inside the electric box allows to exclude the differential relay in case of need from the group to be feeded WARNING Have qualified personnel to exclude protection in order to foresee other electrical safety solutions USE OF THE DER2 D2B MODEL MOSA SET UP 1 Manual
58. icative Hemember that the non observance of the indications reported by us might cause damage 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 A ATTENTION IMPORTANT NOTE 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 da
59. ing light Display Wire connection unit Selector Setting confirmation Fuel valve Oil syringe Insulation monitoring Button indicating light 30 11 PTO HI Engine control unit 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 1 Ammeter Frequency meter Fuse otop 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 Currenttrasformer R P M adjuster Polarity inverter remote control Relas
60. ions and measuring instruments which are protected by a same sized cover 13 11 06 84116 GB M CA GB Quality system MOSA REV 3 02 09 CF THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE IQiNet and its partner CISQ ICIM hereby certify that the organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 1 20081 Abbiategrasso MI Operative Units Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 1 20090 Cusago MI for the following field of activities Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2000 lssued on 2009 03 06 Validity date 2012 03 05 Registration Number 1 3722 Foa i Cl 5Q d i 27 A Ren Wasmer Gilanrenzo Prati President of IONET President af CISQ Iis et pariners AENOR Spain AFAQ AFNOR Froace Intemational Belum ANCE Merico Portugal CIS ja UC Chia COM OOS Crech Republic Cro Cen DOS Germany DS Denmark ELOT Greece FCAV FONDONORMA Eracmela HEQAA Hang Kong Chi IOONTEC Colombia IMNE Inspecta C ATA RAM Argentina JOA Japos Koro MSZT Avago Nomko AS Norway NSAI fond PCBC Poland QM Canada Quality Asaria Austria RE Rusa SAI Global dass SI larani SEQ Move
61. mage can happen to persons or things HIGH VOLTAGE Attention High Voltage 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 PCP e BP 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 A It is compulsory to use the personal protection means given in equipment Use only with safety protections Itis a
62. mbi Spare parts Ersatzteile Tabla de recambios GE 85 115 SKID PSX PMSX 1 09 09 de rechanges Descr Note MOTORE PERKINS PERKINS ENGINE 1104C 44TAG2 GE 115 MOTORE PERKINS PERKINS ENGINE 1104C 44TAG 1 GE 85 ALTERNATORE ALTERNATOR STAMFORD GE 115 PSX ALTERNATORE ALTERNATOR MARELLI GE 115 PMSX Da REV 1 09 09 Del 101 08 08 05 08 ALTERNATORE ALTERNATOR STAMFORD GE 85 PSX ALTERNATORE ALTERNATOR MARELLI GE 85 PMSX Da REV 1 09 09 Del 101 08 08 05 08 FILTRO PER GASOLIO FUEL FILTER CARICAMENTO LATERALE OLIO SIDE OIL FILLER UNIT ANTIVIBRANTE VIBRATION DAMPER SPESSORE 4mm THICKNESS 4mm TRAVERSA SUPPORTO ALTERNATORE TAPPO 1 GAS CONICO TAPPO 1 2 GAS CONICO SERBATOIO CARBURANTE FUEL TANK FONDO BASAMENTO BASE BOTTOM BASAMENTO BASE TAPPO SERBATOIO FUEL TANK CAP SENSORE LIVELLO CARBURANTE FUEL LEVEL SENSOR MORSETTO 35mmq TERMINAL 35mmq GUIDA PER MORSETTIERA TERMINAL GUIDE PIASTRINA PLATE BATTERIA BATTERY 12V 100Ah STAFFA FISSAGGIO BATTERIA BATTERY BRACKET SUPPORTO BATTERIA BATTERY SUPPORT SPINOTTO PLUG SUPPORTO SCATOLA APP ELETTR SUPPORT ELECTRICAL EQUIPMENT SCATOLA APPARECCH ELETTRICHE ELECTRICAL EQUIPMENT ROLL BAR ROLL BAR TUBO SCARICO OLIO EXHAUST OIL PIPE STAFFA SUPP POMPA SCARICO OLIO BRACKET FOR OIL DISCHARGE PUMP POMPA SCARICO OLIO EXHAUST OIL PUMP TRAVERSA SUPPORTO ALTERNATORE ALTERNATOR
63. mustto use protection means suitable for the different welding works Use 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 in 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 B 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 f 23 4 Me k 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 of maintenance 26 11 99 M2 1GB CD MUSA INSTALLATION AND ADVICE BEFORE USE GE MS TS OMOSA 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 us
64. ngs or other plants Maximum leaning of the machine in case of dislevel A 20 max 10 Check that the 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 not move during the work block it possibly with tools and or devices made to this purpose 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 N 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 MOSA MOSA REV 1 04 08 CD Installazione Luftzirkulation Installation Instalaci n Installation 0 LL GE 85 115 SKID PSX 5 13 11 06 84116 1 CD LISA unpacking GE MS_ TS OMOSA 1 1 02 04 CE t 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 prod uct has not suffered damage during the transport that there has not been rough handling or taking away of parts contained i
65. nside 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 e 8 22111 1 Take the machine C 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 AND SKID GE MS TS O MOSA 1 0 03 00 CEO 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 CTL accessory If you did not keep to the instructions you could damage the structure of the machine 30 03 00 M4GB
66. r 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 12 06 03 M20 R HO2 GB AD M SA Set up for operation MOSA 1 0 06 03 CF 23 COOLING LIQUID N ATTENTION Do not remove the radiator tap with the motor in operation or still hot as the liquid coolant may spurt out and cause serious burns Remove the tap very carefully Remove the tap and pour the liquid coolant into the radiator the quantity and composition of the liquid coolant are indicated in the motor operating manual Replace the tap ensuring it is perfectly closed After refilling operations allow the motor to run for a brief time and check the level as it may have diminished due to air bubbles present in the cooling circuit restore the level with water To replace the liqui
67. relay Micro switches for setting up of the instrument Trial push button Push button for the manual reset D4 D5 D6 D7 D8 04 0 5 0 1 02 o5 Fie SS T DI PAIS 0 25 025 02 Qa E DS Fault On Trip 3 SS Sf D 6 IA x 10 2 LO D tx 15 x 10 Lu Reset mul D 8 25 05 01 M39GB EP6 OEM s Manual Contents 1 0 Introduction M39 12 2 0 Operating Mode selection M39 12 2 1 AUTO operating mode M39 12 2 2 MANUAL operating mode M39 12 2 3 OFF operating mode M39 12 3 0 DISPLAY features M39 12 4 0 ALARM messages M39 12 1 4 1 Operating Messages M39 12 1 5 0 LEDs for visual indication M39 12 1 5 1 LEDs and Display Test M39 12 1 6 0 Parameters and Settings M39 12 1 7 0 Remote Start M39 12 4 8 0 Safety M39 12 4 9 0 Automatic Periodic Test M39 12 4 10 0 Front Panel Description M39 12 4 11 0 Dimensions and Rear View 9 12 4 1 0INTRODUCTION The EP6 features Engine and Generating Set control and monitoring The EP6 provides visual indication by means of LEDs solid state lamps and a Display see section 10 0 It features OFF MAN and AUTO operating modes The display gives Messages for alarms and Measurement indications 2 0 OPERATING MODE selection The EP6 features AUTO section 2 1 MANUAL section 2 2 and OFF section 2 3 operating modes When the power supply is switched on the EP6 behaves as follow A if the KEY SWITCH is in the OFF position the EP6 enters the OFF op
68. s SIRIM CAS Inscrmanonal Malmo SUS sitema SRAC Roma TEST 53 Petersbang Serbia KNet Mei represented m the USA AFAQ AFNOR ATB Vingoite International CES DOS NSAI lnc HM and SAI Global The list of IOMa partners is valid at the time of issue of this certificate Updated information is available under www ignet certification com C 5 UNI EN ISO 9001 2000 ISO 9001 2000 Cert 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 ICIM 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 MI 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 CERTIFICATO n CERTIFICATE No BI CERTIFICA CHE IL SISTEMA DI GESTIONE PER L QUALITA WE HERESY CERTIFY THAT THE QUALITY MANAGEMENT SYSTEM OPER
69. scribed in the next section 7 1 REMOTE START SWITCH If the REMOTE START input is activated the AUTO yellow LED illuminates continuously and the display will indicate the count down of the internal start delay timer by means of the message 55 Minutes and seconds The engine will start after the programmed start delay time If the REMOTE START is deactivated the EP6 drives the stop delay time The display will indicate the count down by means of the message MM SS Minutes and seconds and the AUTO yellow LED will flash The engine will stop after the programmed stop delay time Note start delay time see section 6 0 parameter 0 Note stop delay time see section 6 0 parameter P 1 8 0 SAFETY High voltage is present inside the EP6 To avoid electric shock hazard operating personnel must not remove the protective cover Do not disconnect the grounding connection Any interruption of the grounding connection can cre ate an electric shock hazard Before making external connections always ground the PANEL first by connecting the control panel to ground 9 0 Automatic periodic TEST The EP6 does not use a clock to count the programmed days P 26 setting section 6 0 The maximum error and drift of the counter is 0 5 The user may experiment with shifting the periodic tests To avoid error accumulation and in case your unit is programmed to allow Automatic Periodic EP6 ENGINE PROTECTION T
70. sition momentary position with spring loaded return until the engine starts The message TUA indicates a MANUAL start D To stop the engine turn the KEY SWITCH to OFF NOTE EP6 shows the blinking StA message for 20 seconds After this time if the engine does not start the EP6 displays the message FAIL Fail to start see section 4 07 To clear the alarm turn the KEY SWITCH to OFF 2 3 OFF operating mode This function is obtained by turning the KEY SWITCH to OFF The OFF operating mode clears the fault alarms and shuts down the Display after 5 seconds A blinking dot indicates the presence of the power supply Press one of the pushbuttons to energize the display In OFF operating mode the EP6 allows reading of the parameters see section 6 0 3 0 DISPLAY features The EP6 features a 4 Digit Display section10 0 to show measurements settings and error messages The UP DOWN pushbutton selects one of the following menus AXXX Generator Current measurement UXXX The Voltage of the Generating Set rPM XXXX Speed of the engine HXX X Frequency of the Generator bXX X Battery Voltage CXX X Charger Alternator Voltage h XXXX HOUR METER the message h appears for a moment and then the counter will be displayed continuously the symbol X means a numerical field 12 10 05 M39GB CD PROTECTIONS 1 0 10 05 4 0 ALARM messages The alarms are displayed by means of messages
71. sk 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 a 1 meter 95 dB A 8 dB A 87 dB A Lp a 7 meters 95 dB A 25 dB A 70 dB A Lp 4 meters 95 dB A 20 dB A 75 dB A Lp a 10 meters 95 dB A 28 dB A 67 dB A PLEASE NOTE the symbol when with acoustic noise values indicates that the device respects noise emission limits according to 2000 14 CE directive 13 11 06 84116 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 in 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 ind
72. sockets use these sockets for connecting the loads In other cases always use the phase and Neutral ELECTRIC PROTECTIONS THERMAL MAGNETIC SWITCH The electricity generating group is protected against short circuits and against overloads by a thermal magnetic switch Z2 situated upstream from the installation Operating currents both thermic and magnetic can be fixed or adjustable in relation to the switch model c models with adjustable operating current do not modify the settings since doing so can compromise the installation s protection or the electricity generating group s output characteristics For eventual variations contact our Technical Service Department The intervention of the protection feature against overloads is not instantaneous but follows a current overload time outline the greater the overload the less the intervention Furthermore keep in mind that the nominal operating current refers to an operating temperature of 30 C so that each variation of 10 roughly corresponds to a variation of 596 on the value of nominal current In case of an intervention on the part of the thermal magnetic protection device check that the total absorption does not exceed the electricity generating group s nominal current ADO 12 06 03 M37GB_1500G_GE ID M SA Using the generator MOSA 1 1 09 05 CF DIFFERENTIAL SWITCH The differential switch or differential relay guarantee protec
73. tion against indirect contacts due to malfunction currents towards the ground When the device detects a malfunction current that is higher than the nominal current the set current it RESET intervenes by cutting off power to the circuit connected In the case of an intervention by the differential switch check that there are no sheathing defects in the installation connection cables sockets and plugs utilities connected c Before each work session check the operation of the differential protection device by pressing the test key The electricity generating group must be in operation and the lever on the differential switch must be in the ON position THERMIC PROTECTION Generally present to protect against overloads on an individual power socket c a When the nominal operating current has been exceeded the protection device intervenes by cutting off power to the socket The intervention of the protection device against overloads is not instantaneous but follows a current overload time outline the greater the overload the less the intervention In case of an intervention check that the current absorbed by the load does not exceed the protection s nominal operating current Allow the protection to cool off for a few minutes before resetting by pressing the central pole ID mw i DD OFF PRESS 18 Do keep the central pole on thermic protection forcefully pressed to prevent its int
74. tion to the pages concerning the security see page M1 1 MOSA O 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 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 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
75. ts subject to 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 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 operating conditions freq
76. ty 8 8 Starter Electric Electric GENERAL SPECIFICATIONS Battery 12V 100Ah 12V 100Ah Tank capacity 230 230 Running time 75 to PR P 16h 13 5 h Protection IP 44 IP 44 Dimensions max on base Lxwxh mm 2 40 2000 skid x1200x1640 2 40 2000 skid x1200x1640 Weight on base Kg 1425 5 1655 5 1620 5 1450 SKID 1680 PSX 1665 PMSX Measured acoustic power Lwa pression LpA 95 db A 70 db A Q 7m m 96 db A 71 db A 7m Garanteed acoustic power Lwa pression LpA 96 db A 71 db A sere 97 db A 72 db A e Dimensions and weight are inclusive of all parts OUTPUT Declared power according to ISO 8528 1 temperature 25 C 30 relative humidity altitude 100 m above sea level Stand by maximum available power for use at variable loads for a yearly number of hours limited at 500 h No overload is admitted Prime power P R P maximum available power for use at variable loads for a yearly illimited number of hours The average power to be taken during a period of 24 h must not be over 80 of the P R P Its admitted overload of 1096 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 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 ri
77. uent 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 IN THE OWNER S ENGINE MANUAL 05 09 05 M43GB CD Es GS maintenance MOSA _ 100905 N ATTENTION Maintenance operations on the electricity generating group prearranged for automatic operation must be carried out with the panel in RESET mode m Maintenance operations on the installation s electrical panels must be carried out in complete safety by cutting off all external power sources ELECTRICAL POWER GROUP and BATTERY For the electricity generating groups prearranged for automatic operation in addition to carrying out all periodic maintenance operations foreseen for normal usage various operations must be carried out that are necessary in relation to the specific type of use The electricity generating group in fact must be continuously prepared for operation even after prolong
78. up of several motors subdivide the motors into groups and set up their start up at intervals of 30 60 seconds when the operating machine coupled to the motor allows it see to a start up with reduced voltage star point triangle start up or with autotransformer or use a soft start system In all cases when the user circuit requires the start up of an asynchronous motor it is necessary to check that there are no utilities inserted into the installation which in the case of a voltage droop can cause more or less serious disservices opening of contact points temporary lack of power to control and command systems etc SINGLE PHASE LOADS Power to monophase utilities by means of three phase generators requires some operating limitations In single phase operation the declared voltage tolerance can no longer be maintained by the regulator compound or electronic regulator since the system becomes highly unbalanced The voltage variation on the phases not affected by the power can prove dangerous we recommend sectioning the other loads eventually connected GE _ Diesel engine The maximum power which can be drawn between Neutral and Phase start connection is generally 1 3 of the nominal three phase power some types of alternators even allow for 40 Between two Phases triangle connection the maximum power cannot exceed 2 3 of the declared three phase power In electricity generating groups equipped with monophase
79. ur possession GE MS TS EAS 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 potential intervention will fall on the executioner as in fact he becomes maker of the machine t Notice this manual does not engage MOSA who keeps the faculty apart the essential characteristics of the
80. value which depends on the load s electrical specifications it indicates the ratio between the Active Power KW and Apparent Power kVA The apparent power is the total power necessary for the load achieved from the sum of the active power supplied by the motor after the alternator has transformed the mechanical power into electrical power and the Reactive Power supplied by the alternator The nominal value for the power factor is cos o 0 8 for different values comprised between 0 8 and 1 it is important during usage not to exceed the declared active power KW so as to not overload the electricity generating group motor the apparent power kVA will diminish proportionally to the increase of cos q For cos o values of less than 0 8 the alternator must be downgraded since at equal apparent power the alternator should supply a greater reactive power For reduction coefficients contact the Technical Service Department START UP OF ASYNCHRONOUS MOTORS The start up of asynchronous motors from an electricity generating group can prove critical because of high start up currents the asynchronous motor requires 1 start up up to 8 times the nominal current In The start up current must not exceed the alternator s admissible overload current for brief periods generally in the order of 250 300 for 10 15 seconds To avoid a group oversize we recommend following these precautionary measures in the case of a start

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