Manual

0 7 0 6

GE 275 VPS - VPSX

842769003 - GB

ISTRUCTIONS MANUAL

11/07/06 84276M00 preparato da UPT approvato da DITE

© MOSA 1.2-05/03

Quality system GE_, MS_, TS_, EAS_

M

01

UNI EN ISO 9001 : 2000

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.

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 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

© MOSA REV.0-07/06

INDEX

M 1.01

M 1.1

M 1.4

M 2 ...

COPYRIGHT

NOTES

NOTES

SYMBOLS AND SAFETY PRECAUTIONS

M 2.5 -… ADVICE

M 2.6

INSTALLATION AND ADVICE

M 3

M 4.2

UNPACKING

TRANSPORT AND DISPLACEMENTS

M 20

M 21

SET-UP FOR OPERATION

START AND STOP

M 31 CONTROLS

M 33 ...

USE OF THE GECO CONTROL UNIT

M 37 -… USING THE GENERATOR

M 38.6

TCM 35 REMOTE CONTROL

M 39.11

EARTH LEAKAGE RELAY

M 39.12... EP6 ENGINE PROTECTION

M 40 TROUBLE-SHOOTING

M 43 -… MAINTENANCE OF THE MACHINE

M 45

M 46

STORAGE

CUST OFF

M 51

M 60

TECHNICAL DATA

ELECTRICAL SYSTEM LEGEND

M 61-… ELECTRICAL SYSTEM

GE 275 VPS - VPSX

M

1

Copyright

© MOSA 1.0-10/02

!

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.

We advise you to pay attention to the pages concerning the security (see page M1.1).

ã

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

M

1.01

Notes

© MOSA 1.0-10/02

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.

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.

The use of non original spare parts will cancel

immediately any guarantee and Technical Service 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 your possession.

GE_, MS_, TS_, EAS_

M

1-1

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 it is 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.

Notice: this manual does not engage MOSA, who keeps the faculty, apart the essential characteristics of the model here described and illustrated, to bring betterments and modifications to parts and accessories, without putting this manual uptodate immediately.

© MOSA 1.2-06/03

CE MARK GE_, MS_, TS_, EAS_

M

1.4

The CE mark (European Community) certifies that the product complies with the essential safety requirements provided by the applicable COMMUNITY DIRECTIVES. In the Conformity

Declaration are reported the HARMONIZED NORMS and not, used for the checking.

SYMBOLS AND SAFETY PRECAUTIONS

© MOSA 1.0-11/99

SYMBOLS IN THIS MANUAL

GE_, MS_, TS_

SAFETY PRECAUTIONS

M

2

-

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.

!

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.

IMPORTANT ADVICE

- Advice to the User about the safety:

N.B.: 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 indicative.

Remember 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

This heading warns of situations which could result in injury for persons or damage to things.

!

CAUTION

To this advice can appear a danger for persons as well as for things, for which can appear situations bringing material damage to things.

WARNING

!

Situations of danger - no harm to persons or things

!

!

IMPORTANT

NOTE

!

ATTENTION

These headings refer to information which will assis you in the correct use of the machine and/or accessories.

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

© MOSA 1.1-04/03

SYMBOLS

(for all MOSA models)

STOP - Read absolutely and be duly attentive

GE_, MS_, TS_

M

2-1

PROHIBITIONS

No harm for persons

Use only with safety clothing -

It is compulsory to use the personal protection means given in equipment.

!

Read and pay due attention

GENERAL ADVICE - If the advice is not respected damage 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.

Use only with safety clothing -

It is compulsory to use the personal protection means given in equipment.

Use only with safety protections -

It is a must to 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.

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.

ADVICE

No harm for persons and things

Use only with safety tools, adapted to the specific use -

It is advisable to use tools adapted to the various maintenance works.

Use only with safety protections, specifically suitable

It is advisable to use protections suitable for the different welding works.

Use only with safety protections -

It is advisable to use protections suitable for the different daily checking works.

Use only with safety protections -

It is advisable to use all protections while 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.

ACCES FORBIDDEN to non authorizad peaple.

INSTALLATION AND ADVICE BEFORE USE GE_, MS_, TS_

M

2-5

© MOSA 1.0-06/00

!

The installation and the general advice concerning the operations, are finalized to the correct use of the machine, in the place where it is used as generator group and/or welder.

Stop engine when fueling

Do not smoke, avoid flames, sparks or electric tools when fueling.

Do not touch electric devices if you are barefoot or with wet clothes.

Unscrew the cap slowly to let out the fuel vapours.

Slowly unscrew the cooling liquid tap if the liquid must be topped up.

Always keep off leaning surfaces during work operations

The vapor and the heated cooling liquid under pressure can burn face, eyes, skin.

Static electricity can demage the parts on the circuit.

Do not fill tank completely.

Wipe up spilled fuel before starting engine.

Shut off fuel of tank when moving machine (where it is assembled).

Avoid spilling fuel on hot engine.

Sparks may cause the explosion of battery vapours

An electric shock can kill

FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas 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

Eyes contact

Ingestion

Suction of liquids from lungs

Inhalation

Wash with water and soap

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

If you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take the subject to the hospital with the utmost urgency

In case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved

FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable to cause severe wounds or death, follow the first aid as described by the ruling norms or local ones.

Appropriated

Not to be used

Other indications

Particular protection

Useful warnings

EXTINCTION MEANS

Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water

Avoid the use of water jets

Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces close to the fire

Wear an autorespiratory mask when heavy smoke is present

Avoid, by appropriate means to have oil sprays over metallic hot surfaces or over electric contacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep in mind that the inflamability point is very low.

!

WARNING

!

CAUTION

!

WARNING

THE MACHINE MUST NOT BE USED IN AREAS WITH

EXPLOSIVE ATMOSPHERE

INSTALLATION AND ADVICE GE_, MS_, TS_

M

2.6

© MOSA 1.0-11/99

INSTALLATION AND ADVICE BEFORE USE

Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature.

GASOLINE ENGINES

Use in open space, air swept or vent exhaust gases, which contain the deathly carbone oxyde, far from the work area.

1,5 m

DIESEL ENGINES

■ Use in open space, air swept or vent exhaust gases far from the work area.

1,5 m

1,5 m

POSITION

Place the machine on a level surface at a distance of at least 1,5 m from buildings or other plants.

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

In spots where it often rains and/or there are flooded areas, do not put the machine:

■ in the bad weather in flooded places.

Protect all the electric parts at risk, because water infiltrations could cause short circuits with damages at persons and/or things.

The protection degree of the machine is put on the data plate and in this manual at page "Technical Data".

Maximum leaning of the machine (in case of dislevel)

© MOSA REV.0-07/06

Installazione

Installation

Installation

D

E

NL

Luftzirkulation

Instalación GE 275 VPS - VPSX

M

2.7

© MOSA 1.1-02/04

UNPACKING

!

GE_, MS_, TS_

M

3

NOTE

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 regulations.

When receiving the goods make sure that the product has not suffered damage during the transport, that there has not been rough handling or taking away of parts contained inside the packing or in the set.

In case you find damages, rough handling or absence of parts (envelopes, manuals, etc.), we advise you to inform immediately our Technical Service.

For eliminating the packing materials, the User must keep to the norms in force in his country.

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.

TRANSPORT AND DISPLACEMENTS COVERED UNITS AND SKID GE_, MS_, TS_

M

4-2

© MOSA 1.0-03/00

!

NOTE

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.

IT IS 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.

© MOSA 1.1-09/05

Set-up for operation TS_,DSP_,GE

Water cooled systems

M

20

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.

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.

!

FUEL

LUBRICANT

RECOMMENDED OIL

MOSA recommends selecting AGIP engine oil.

Refer to the label on the motor for the recommended products.

ATTENTION

Do not smoke or use open flames during refuelling operations, in order to avoid explosions or fire hazards.

Fuel fumes are highly toxic; carry out operations outdoors only, or in a wellventilated environment.

Avoid accidentally spilling fuel. Clean any eventual leaks before starting up motor.

Please refer to the motor operating manual for the recommended viscosity.

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.

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.

Set-up for operation

© MOSA 1.0-06/03

COOLING LIQUID

!

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 liquid 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_,GE

Water cooled systems

M

20.

1

© MOSA REV.0-07/06

Check daily

START AND STOP GE 225 VPS - VPSX

GE 275 VPS - VPSX

M

21

!

NOTE

Do not alter the primary conditions of regulation and do not touch the sealed parts.

The starting of the unit can be effected in 2 different modes:

1) Start with EP6 key (Engine Control)

Put the “SWITCH BOARD” selector on ON. 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 can be fixed.

Stop: it is COMPULSORY to disconnect the load first, then to stop the engine turn the key on “OFF”.

!

CAUTION

MACHINE WITH EMERGENCY BUTTON

Pressing the button the engine will stop immediately in any working condition.

Turn clockwise to reset the button.

2) Remote starting with TCM35

Put the “SWITCH BOARD” selector on ON.

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 “I” in the TCM35 and automatically the starting cycle will start. On the machines with mounted glow plugs appears in the display EP6 (for about 5 secs), the symbol

“UUUU“; the starting cycle includes 3 starting trials.

When the engine starts the led “AUTO” remains lit continuously and simultaneously the red warning light will light in the TCM35.

Stop:

it is COMPULSORY to disconnect the load first, then shift the switch of the TCM35 on “0”, the engine will stop immediately.

!

CAUTION

RUNNING-IN

During the first 50 hours of operation, do not use more than 60% of the maximum output power of the unit and check the oil level frequently, in any case please stick to the rules given in the engine use manual.

!

NOTE

For safety reason the key must be kept by qualified personel.

© MOSA REV.0-07/06

Comandi

Controls

Commandes

D

E

NL

Mandos GE 275 VPS - VPSX

M

31

V5

Z5

D6

E6

A7

Q3

R3

L5

T5

Pos.

X1

C2

D2

H2

Z2

C7

E7

N7

U7

Descrizione

Presa comando a distanza

Indicatore livello combustibile

Amperometro

Commutatore voltmentrico

Int. magnetot./differenziale

Muffola

Avvisatore acustico

Pulsante stop emergenza

Relè differenziale di terra

Indicatore pressione olio

Indicatore temperatura acqua

Connettore PAC

Potenz.regolatore di giri/Freq.

Selettore travaso pompa AUT-0-

MAN

Controllo gruppo elettr. “GECO”

Potenz. regolatore di tensione

Selettore OFF-ON-DIAGN.

Protezione motore EP6

Description Description

Remote control socket

Fuel level gauge

Ammeter

Voltage selector switch

Thermal-magnetic circuit breaker/GFI

Output power unit

Electric siren

Emergency stop button

Earth leakage relay

Oil pressure indicator

Water temperature indicator

Connector, PAC

Frequency rpm regulator

Transfer pump selector AUT-0-

MAN

“GECO” generating set test

Voltmeter regulator

OFF-ON-DIAGN. selector

Engine protection EP6

Prise télécommande lndicateur niveau carburant

Ampéromètre

Commutateur de tension lnterrupteur magnétothermique/ différentiel

Planche à bornes prélèv. puissance

Avertisseur sonore

Bouton d’urgence

Relais différentiel de terre

Indicateur pression huile

Indicateur température eau

Connecteur PAC

Potentiomètre régul. de fréquence t/m

Sélecteur transvasement pompe AUT-

0-MAN

Contrôle groupe électrogene "GECO"

Potentiomètre régulateur de tension

Sélecteur OFF-ON DIAGN

Protection moteur EP6

Descripción

Toma mando a distancia

Indicador nivel carburante

Amperímetro de línea

Conmutador voltimétrico

Interruptor magnetotérmico / diferencial

Terminal obtención potencia

Sirena

Pulsador emergencia

Relé diferencial de tierra

Indicador presión aceite

Indicador temperatura agua

Conector PAC

Potenciom.regul. de vueltas/freq.

Selector trasvase bomba AUTO/

0/MAN

Control grupo electrógeno "GECO"

Potenc. regulador de tensión

Selector OFF-ON DIAGN

Protección motor EP6

© MOSA 1.0-09/02

USE GE 225 - 275 VPS - VPSX

M

33

INTRODUCTION

The “GECO” equipment entails a control unit for absolutely modern generators. Its strong holds are the following:

- Large-size graphical display (95x45 mm) to be able to display all the electrical parameters at the same time (with characters of 10mm).

- The membrane keyboard has built-in keys with relative indicator LEDs. It also offers a high degree of reliability and ideal touch-sensitive keys.

- The HELP key with relative LED that flashes to point out that a message is to be read

- The use of the dater clock to set the weekly TEST and to display all the events that occur and that may be shown on the Display.

- The control of 4 different mains/generator line systems:

• N-L1-L2-L3

• L1-L2-L3

• L1-N-L2 (AMERICAN market)

• N-L1

- Operational temperature range from -20 to + 60°C

- Protection rating IP64

- 5 possible languages: Italian-English-French-German-

Spanish

- Generator protection against OVERLOADS and SHORT-

CIRCUITS with setting of the rated current of the generator, setting of the short-circuit current in percentage of the rated current value of the generator and a tripping delay timing of the protection device in tenths of a second.

Parameters Displayed

The LCD shows data and information in graphic and alphanumeric forms. Press the “

⇓⇓⇓⇓⇓” or “⇑⇑⇑⇑⇑” keys to view the data pages. Press the “” or “+” keys to see alternative data on the same page.

N.B. on the display it appears MAINS or GENERATOR for showing to whom the measure are referred.

The measure on the display are the followings:

Battery voltage

Mains and phase generator voltages, between the lines and of the system

Phase currents

Phase and total active, reactive and apparent powers.

Active, reactive and apparent energy.

P.F. - Power factor of each phase.

Energy contact maker

Frequency of the generator.

Oil pressure instrument

Water temperature instrument

Fuel level instrument

Engine RPM

Number of successful starting attempts

Number of failed starting attempts

Number of total starting attempts

Total hours of use

Partial hours of use

Hours left to maintenance

KEYBOARD

HELP key – The illuminated LED means a help message is available. By pressing the key, a help message concerning the current operation is displayed.

ENTER and EXIT keys - Press ENTER to confirm operations or to enter the menu. Press EXIT to refuse an operation or to exit a menu and help message.

⇓⇓⇓⇓⇓” and “⇑⇑⇑⇑⇑” arrow keys – Press these keys to shift to the different pages of data display or to select parameters.

“–” and “+” keys Press these keys to display alternative data of the selected data page or to modify the parameters.

OFF/RESET, MAN, AUT and TEST keys – Press these keys to select the operating mode. The illuminated LED indicates the selected operating mode; if it is flashing, remote control is active.

USE

© MOSA 1.0-09/02

START and STOP keys – These work in MAN operating mode only, used to start and stop the engine. By quickly pressing the START key, one start attempt takes place; by keeping the START key pressed, the duration of the start attempts can be extended. The flashing LED of the engine symbol denotes engine started, with alarms inhibited; and is constantly on at the end of the alarms inhibition time. The engine can be stopped using the OFF/RESET key.

MAINS and GEN keys – They work in MAN operating mode only, used to switch the load from mains to generator and vice versa. The illuminated LEDs of the mains and generator symbols indicate the respective voltages are within preset limits. The illuminated LEDs of the changeover symbols indicate the actual closing of switching devices; when flashing, there is a incorrect feed-back signal for the actual closing or opening of the switching devices.

OPERATING MODE

OFF/RESET mode – The engine can not operate. If the mains is present, the load is switched to the mains. Changing from

TEST, AUT or MAN to the OFF/RESET mode and if the engine is running, the engine is immediately stopped and eventual alarms are reset. If the cause of the alarm is still present, it can not be reset.

MAN mode – The engine can be manually started or stopped using the START and STOP keys only in addition to load switching from mains to generator and vice versa, by means of the MAINS and GEN keys. Always in MAN mode, at the start command and by keeping the key pressed, the preset starting time can be prolonged while at the stop command and by keeping the key pressed for more than 6 seconds, the fuel valve is discharged for 4 minutes.

AUT mode – In case of mains not present (out of the preset limits), the engine automatically starts or stops when the mains returns.

TEST mode – The engine immediately starts even if the mains is present. In case the mains is not present, the load is switched to the generator. Changing to the AUT mode and if the mains is present, the engine will stop.

Alarms

When an alarm arises, the lower section of the display is used to view it. In case of two alarms or more, they are individually shown in sequence. A help message is available for every alarm, in order to locate the possible alarm source. Alarm conditions can be reset by means of the OFF/RESET key, that prevent any unintentional engine starting at the alarm reset operation. If the alarm does not reset, this means the cause of the alarm is still present. During event-log sessions and set-up operations, no alarms are viewed.

GE 225 - 275 VPS - VPSX

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USE

© MOSA 1.0-09/02

LIST OF THE ALARMS GECO

A01 Engine temperature warning (analog sensor)

A02 High engine temperature (analog sensor)

A03 Temperature analog sensor fault

A04 High engine temperature (digital sensor)

A05 Oil pressure warning(analog sensor)

A06 Low oil pressure (analog sensor)

A07 Pressure analog sensor fault

A08 Low oil pressure (digital sensor)

A09 Pressure digital sensor fault

A10 Fuel level warning(analog sensor)

A11 Low fuel level(analog sensor)

A12 Level analog sensor fault

A13 Low fuel level(digital sensor)

A14 High battery voltage

A15 Low battery voltage

A16 Inefficient battery

A17 Charger alternator failure

A18 “W” signal failure

A19 Low engine “W” speed

A20 High engine “W” speed

A21 Starting failure

A22 Emergency stop

A23 Unexpected stop

A24 Engine stop failure

A25 Low generator frequency

A26 High generator frequency

A27 Low generator voltage

A28 High generator voltage

A29 Generator asymmetry

A30 Generator short-circuit

A31 Generator overload

A32 External generator protection tripping

A33 Incorrect generator phase sequence

A34 Incorrect mains phase sequence

A35 Wrong system frequency setting

A36 Generator contactor failure

A37 Mains contactor failure

A38 Maintenance requested

A39 System error

A40 Fuel transfer empty

A41 Fuel transfer too full

A42 Rent hours exhausted

GE 225 - 275 VPS - VPSX

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2

UA1 Earth leakage relay protection

UA2 User’s alarm 2

UA3 User’s alarm 3

UA4 User’s alarm 4

N.B.: MOSA enables the alarms and sets their intervention characteristics according to the type of generating set.

USE

© MOSA 1.0-09/02

TECHNICAL CHARACTERISTICS GECO

Power supply

Battery rated voltage

Voltage range

12 or 24VDC indifferently

9

÷

33VDC

Minimum voltage at the starting 6,7VDC

Maximum current consumption 320mA at 12VDC and

160mA at 24VDC

Stand-by current

Micro interruption immunity

150mA at 12VDC and

75mA at 24VDC

200ms

Digital input

Input type

Current input

Input “low” voltage

Input “high” voltage

Input delay negative

10mA

≤1,5V (typical 2,9V)

≥5,3V (typical 4,3V)

≥50ms

Speed input “W”

Input type

Voltage range

Frequency range

AC coupling

5

÷50Vpp

40

÷2000Hz

Engine running input (500rpm) for permanent magnet generator

Voltage range 0

÷

40VAC

Engine running input (500rpm) for pre-excited generator

Voltage range 0

÷

40VDC

Maximum input current 12mA

Maximum voltage at +D terminal 12 or 24VDC (battery voltage)

Pre-excitation current 170mA at 12VDC or

130mA at 24VDC

Relay output 4.1-4.2 / 4.3-4.4 terminals (voltage free)

Contact type 1 NC for mains 1 NO for

Rated voltage

Rated current at 250VAC generator

250VAC (440VAC max)

8A AC1 (2A AC15)

Relay output 5.3-5.4-5.5 terminals (voltage free)

Contact type

Rated voltage

Rated current at 250VAC

1 changeover

250VAC max

8A AC1 (2A AC15)

Relay output 6.2 / 6.3 / 6.4 / 6.5 terminals (+ battery voltage output)

Contact type

Rated voltage

Rated current at 30VDC

1 NO

30VDC

5A DC1

Analog inputs

Pressure sensor current

Temperature sensor current

Level sensor current

Analog ground voltage

Voltage inputs

Maximum rated voltage Ue

Measuring range

Frequency range

Measuring method

Measuring input impedance

Wiring mode

20mA max

7mA max

10mA max

-0,5V

÷+0,5V

480VAC L-L (277VAC L-

N)

50

÷620V L-L (358VAC L-

N)

45

÷65Hz

True RMS

>1,1MW L-L >570kW L-

N

1, 2 or 3 phases, with or without neutral

GE 225 - 275 VPS - VPSX

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33.

3

Current inputs

Rated current Ie

Measuring range

Measuring method

Overload capacity

5A

0,02

÷

6A

True RMS

+20% Ie

Overload peak

Power consumption

50A for 1 second

<

0,3VA

Measuring charateristics (-10

Voltage

Frequency

Current

Power

Energy

÷÷÷÷÷

+45°C)

±

1%

±

1digit

±

0,2%

±

1digit

±

1%

±

1digit

±

2%

±

1digit

±

2%

±

1digit

Ambient operating conditions

Operating temperature

Storage temperature

Relative humidity

Maximum pollution degree

-20

÷

+60°C

-30

÷

+80°C

<

90%

3

Connections

Terminal type Plug-in

Cable cross section (min e max) 0,2

÷÷÷÷÷2,5 mmq (24÷÷÷÷÷12

AWG)

Tightening torque 0,8 Nm (7 LBin)

Housing

Version

Dimensions

Panel cutout

Material

Degree of protection

Weight

Flush mount

196,5x106,5x120mm

181x91mm

Noryl SE100 thermoplastic

IP64 on front

750g

USE GE 225 - 275 VPS - VPSX

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© MOSA 1.0-09/02

ACQUIRED HOMOLOGATIONS GECO

Type of test/check

Functional characteristics test

Heating test

Electrical tests

Reference standard / regulation

IEC/EN 60255-6 (’94)

IEC/EN 60255-6 (’94)

IEC 60664-1 (’92)

Test parameters

Sect. 3, par. 13 of the standard

Sect. 3, par. 15 of the standard

• 4 kV (1.2/50

Ns): 3 pulses + and 3 pulses – with gap of at least 1 s

• 2500 (50Hz): 1 min.

EMC test

ƒƒƒƒƒ Imunity tests

¾ Surges

¾ fast transient/bursts

¾ irradiated electro-magnetic field

¾ driver electro-magentic field

¾ Electrostatic discharge

ƒ Emission tests

¾ Radiofrequency driver emission

¾ Radiofrequency irradiated emission

Collision

Sinusoidal vibrations

Salty mist

Z/ABDM climatic sequence

IEC/EN 61000-4-5 (’95)

IEC/EN 61000-4-4 (’95)

IEC/EN 61000-4-3 (’96)

IEC/EN 61000-4-6 (’96)

IEC/EN 60255-22-2 (’96)

IEC/EN 55011 (’98)

IEC/EN 55011 (’98)

IEC/EN 60255-21-2 (’95)

IEC/EN 60068-2-6 (LLOYD)

RINA regulation (sect. E chap. 3) or IEC/EN 60068-2-52 (’96)

IEC/EN 60068-2-61 (’93)

2kV (CM) - 1kV (DM)

2kV on power supply and output - 1 kV on controls

10 V/m

10V

8kV (air) - 6kV (contact) class A of the standard class A of the standard class 2 of the standard

V1

According to RINA regulation (past edition) or level 2 of the standard

Temperatures according to storage limits and operational limits

USE

© MOSA 1.0-09/02

Terminal board connections (seen from rear)

GE 225 - 275 VPS - VPSX

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5

Overall dimensions

Using the generator

© MOSA 1.1-09/05

!

WARNING

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 nonauthorized 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 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.

In 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

POWER

The electrical power expressed in kVA on an electricitygenerating group is the available output power to the reference environmental conditions and nominal values for: voltage, frequency, power factors (cos ϕ).

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There are various types of power: PRIME POWER (PRP),

STAND-BY POWER established by ISO 8528-1 and

3046/1 Norms, and their definitions are listed in the manual’s TECHNICAL SPECIFICATIONS page.

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 ϕ = 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 0.1 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 voltage 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 % (static or droop), while under static conditions precision is maintained within ±1%.Therefore, for generators at 50Hz the no-load frequency can be

52–52.5 Hz, while for generators at 60Hz the no-load frequency can be 62.5-63Hz.

Using the generator

© MOSA 1.1-09/05

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 noload to load (isochronal operation).

POWER FACTOR - COS

ϕϕϕϕϕ

The power factor is a 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 (kVAR) supplied by the alternator. The nominal value for the power factor is cos

ϕ = 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 ϕ.

For cos ϕ 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 electricitygenerating group can prove critical because of high start-up currents the asynchronous motor requires (I 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-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.

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1

- 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 sockets, use these sockets for connecting the loads. In other cases, always use the "R" phase and Neutral.

ELECTRIC PROTECTIONS

THERMAL-MAGNETIC SWITCH

The electricity-generating group is protected against shortcircuits 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.

In 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°C roughly corresponds to a variation of 5% 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.

Using the generator

© MOSA 1.1-09/05

DIFFERENTIAL SWITCH

The differential switch or differential relay guarantee protection against indirect contacts due to malfunction currents towards the ground. When the device detects a malfunction current that is higher than the nominal current or the set current, it intervenes by cutting off

A tx10 x1 x10

RESET

1 a 0

1 b 0

1 c 0

1 d 0

M tx1 x0.1I°

T5.9

T5.10

T5.3

T5.2

T5.5

0.5

RESET

1 1.5

2

0.25

I° (A)

2.5

A tx10

I° x1

RESET

M tx1 x0.1I°

0.2

TEST

0.3

T5.4

0.1

ON TRIP

0.02

t (s)

0.4

0.5

T5.1

T5.6 T5.7

T5.8

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.

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.

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2

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.

T Perform connections on the installation in safety conditions. Position the automatic panel in RESET or LOCKED mode.

T Carry out the first start-up in MANUAL mode.

Check that the generator’s LOCAL START / REMOTE

START switch (I6) is in the 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.

T 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.

ON OFF

PRESS TO

RESET

!

ATTENTION

Do not keep the central pole on the thermic protection forcefully pressed to prevent its intervention.

TCM 35 REMOTE CONTROL

M

38.6

© MOSA 1.0-03/06

!

MAKE SURE

The selector LOCAL START/REMOTE START (I6) 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 (U7).

For use of TCM 35 see page M21 (start and stop) of this manual.

© MOSA

!

1.1-10/05

Don not intervene on the setting of the protection switch. Before using the machine check the ON warning lamp lighting.

ENGINE PROTECTION USE

NOTE

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.I.

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 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 .

☞ - In order to modify the set up call the Technical

Assistance Centres

The GFI is equipped with three tests, two of which are 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

M

39.11

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.

D4 Led indicating presence of feeding

D5 Led indicating intervention of GFI relay

D6 Micro-switches for setting up of the instrument

D7 Trial push-button

D8 Push-button for the manual reset

PROTECTIONS

© MOSA 1.0-10/05

EP6 OEM’s Manual - Contents

1.0 Introduction

2.0 Operating Mode selection

2.1 AUTO operating mode

2.2 MANUAL operating mode

2.3 OFF operating mode

3.0 DISPLAY features

4.0 ALARM messages

M39.12

M39.12

M39.12

M39.12

M39.12

M39.12

M39.12.1

4.1 Operating Messages

5.0 LEDs for visual indication

5.1 LEDs and Display Test

6.0 Parameters and Settings

M39.12.1

M39.12.1

M39.12.1

M39.12.1

7.0 Remote Start

8.0 Safety

9.0 Automatic Periodic Test

10.0 Front Panel Description

M39.12.4

M39.12.4

M39.12.4

M39.12.4

11.0 Dimensions and Rear View M39.12.4

1.0 INTRODUCTION

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 operating 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

M

39.12

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 position

(momentary position with spring-loaded return) until the engine starts. The message [ . . . .] 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.

PROTECTIONS

© MOSA 1.0-10/05

4.0 ALARM messages

The alarms are displayed by means of messages.

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:

[OIL]

[ °C ]

[O.SPd.]

[U.SPd]

[bELt]

[ALAr]

[FUEL](1)

[FAIL] (3)

[E 05](2)

[Hi H](2)

[Lo H](2)

[Hi U] (2)

[Lo U](2)

[XX.X]

[Err ]

[E 04]

Low Oil Pressure

High Temperature

Over Speed of the engine

Under Speed of the engine

Failure of the belt

External Emergency Stop

Low Fuel in the tank

Starting Failure Alarm

Generator Overload

Generator Over Frequency

Generator Under Frequency

Generator Under Voltage

Generator Under Voltage

Battery Voltage

Memory error

Alternator Failure

(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]

[U— ]

[StA-]

[. . . .]

Glow-plugs timing

Voltage out of range

Start prompt

Starting by key switch

[rESt]

[tESt]

[CAL]

[Pro-]

[rEAd]

Rest timing

Automatic Test

Calibration

Programming

Parameter reading

[StOP]

Stopping cycle

[MM.SS]

Remote Start or Remote Stop cycle

EP6 ENGINE PROTECTION

5.0 LEDs for visual indication

M

39.12.

1

The EP6 features two LEDs (see section 10.0) to indicate the following 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.

PROTECTIONS EP6 ENGINE PROTECTION

M

39.12.

2

© MOSA

Display

1.0-10/05

[P.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]

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 [P20] 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 secondsMaximum insertion time of the Starter Motor.

Engine Running Trigger (Input#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 above 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 Generator failure 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

[bELt]

PROTECTIONS EP6 ENGINE PROTECTION

M

39.12.

3

© MOSA

[P.16]

[P.17]

1.0-10/05

[P.18]

[P.19]

[P.20]

[P.21]

[P.22]

[P.23]

[P.24]

[P.25]

[P.26]

[P.27]

[P.28]

[P.29]

Stop Solenoid Timing [ 2"]

Range: 2-99 secs. Duration of the Stop cycle.

Alarm Output Timing [ 1']

[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

(>4000 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 crank cycle. One seconddelay avoids false termination.The 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 [P17]= [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

PROTECTIONS

© MOSA 1.0-10/05

7.0 REMOTE START

The EP6 features REMOTE START only in AUTO operating mode.

To operate the REMOTE START, follow the instructions.

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 described 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 [MM.SS]

(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

[P.0]

Note

stop delay time: see section 6.0 parameter

[P.1]

8.0 SAFETY

!

NOTE

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 create 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

Button

[F1]

Button

[AUTO]

AUTO (Yellow

Led)

Button

[ENTER] (*)

Key

(OFF-ON-START)

Button [+]

(*)

Button [-] (*)

(*) The use of these buttons is reserved only to the manufacturer of the generating set.

11.0 DIMENSIONS

Closing cover

Rear view

Recommended hole dimensions:

91mm (+/- 0.5) x 91mm (+/- 0.5)

[UP DOWN]

Button

Green LED engine on

M

39.12.

4

Test, 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

Ideograms

4 digits DISPLAY

Front view

Rear cover

Cables outlet

© MOSA REV.3-07/06

Problem

Troubleshooting

The motor does not start up

The motor does not accelerate. Inconstant speed.

Black smoke

White smoke

Too little power provided by motor.

Low oil pressure

High temperature

GE

Diesel engine

Solution

M

40.2

Possible cause

ENGINE

1) Start-up switch (I6) (where it is assembled) in incorrect position

2) Emergency button (L5) pressed

3) Preheating (where it is assembled)

4) Engine control unit or starting key faulty.

5) Battery low

6) Battery cable terminals loose or corroded

7) Start-up motor defective

8) No fuel or air in feed circuit

9) Malfunction on feed circuit: defective pump, injector blocked, etc.

10) Air filter or fuel filter clogged

11) Air in the gasoil filter.

12) Motor stopping device defective

13) Malfunction on electrical power circuit on generator control panel

1) Air filter or fuel filter clogged.

2) Malfunction on feed circuit: defective pump, injector blocked, etc.

3) Oil level too high.

4) Motor speed regulator defective.

1) Air filter clogged.

2) Overload.

3) Injectors defective. Injection pump requires calibration.

1) Oil level too high.

2) Motor cold or in prolonged operation with little or no load.

3) Segments and/or cylinders worn out.

1) Air filter clogged.

2) Insufficient fuel distribution, impurities or water in feed circuit.

3) Injectors dirty or defective.

1) Oil level insufficient

2) Air filter clogged.

3) Oil pump defective.

4) Alarm malfunction.

1) Overload

2) Insufficient ventilation.

3) Insufficient coolant liquid (Only for water cooled motors)

1) Check position

2) Unblock

3) Lacking or insufficient preheating phase for sparkplugs.

Malfunction in circuit: repair.

4) Replace

5) Recharge or replace.

Check the battery charge circuit on motor and automatic panel.

6) Tighten and clean. Replace if corroded.

7) Repair or replace.

8) Refill tank, un-aerate the circuit.

9) Ask for intervention of Service

Department.

10) Clean or replace

11) Take the air out filling the filter with gasoil.

12) Replace.

13) Check and repair.

1) Clean or replace.

2) Ask for intervention of Service

Department.

3) Eliminate excess oil.

4) Ask for intervention of Service

Department

1) Clean or replace

2) Check the load connected and diminish.

3) Ask for intervention of Service

Department.

1) Eliminate excess oil.

2) Insert load only with motor sufficiently hot

3) Ask for intervention of Service

Department.

1) Clean or replace.

2) Check the feed circuit, clean and refill once again.

3) Ask for intervention of Service

Department.

1) Reset level. Check for leaks.

2) Replace filter.

3) Ask for intervention of Service

Department.

4) Check the sensor and electrical circuit.

1) Check the load connected and diminish.

2) Check the cooling vent and relative transmission belts

3) Restore level. Check for leaks or breakage in the entire cooling circuit, pipes, couplings, etc.

© MOSA REV.3-07/06

Problem

Absence of output voltage

No-load voltage too low or too high

Corrected no-load voltage too low with load

Unstable tension

Troubleshooting

Possible cause

ENGINE

4) Water radiator or oil clogged (where it is assembled)

5) Water circulating pump defective (Only for water cooled motors)

6) Injectors defective. Injection pump requires calibration

7) Alarm malfunction

GENERATOR

1) Voltage switch in position 0

2) Voltage switch faulty

3) Protection tripped due to overload

4) Differential protection device tripped.

(Differential switch, differential relay)

5) Protection devices defective

6) Alternator not sparked

7) Alternator defective

1) Incorrect motor running speed

2) Voltage regulating device (where it is assembled) defective or requires calibration

3) Alternator defective

1) Incorrect motor running speed due to overload

2) Load with cos ϕ less than 0.8

3) Alternator defective

1) Contacts malfunctioning

2) Irregular rotation of motor

3) Alternator defective

GE

Diesel engine

Solution

M

40.2.

1

4) Clean cooling fins on radiator

5) Ask for intervention of Service

Department

6) Ask for intervention of Service

Department

7) Check the sensor and electrical circuit

1) Check position

2) Check connections and working of the switch, repair or replace

3) Check the load connected and diminish

4) Check on the entire installation: cables, connections, utilities connected have no defective sheathing which may cause incorrect currents to ground

5) Replace

6) Carry out external spark test as indicated in alternator manual. Ask for intervention of Service

Department

7) Check winding, diodes, etc. on alternator (Refer to alternator manual)

Repair or replace.

Ask for intervention of Service

Department

1) Regulate speed to its nominal noload value

2) Adjust regulator device as indicated in alternator manual, or replace

3) Check winding, diodes, etc. on alternator (Refer to alternator manual)

Repair or replace

Ask for intervention of Service

Department

1) Check the load connected and diminish

2) Reduce or rephase load

3) Check winding, diodes, etc. on alternator (Refer to alternator manual)

Repair or replace

Ask for intervention of Service

Department

1) Check electrical connections and tighten

2) Ask for intervention of Service

Department

3) Check winding, diodes, etc. on alternator (Refer to alternator manual)

Repair or replace

Ask for intervention of Service

Department

MAINTENANCE

M

43

© MOSA 1.0-09/05

MOVING

PARTS can injure

!

WARNING

Have qualified personnel do maintenance and troubleshooting work.

Stop the engine before doing any work inside the machine. If for any reason the machine must be operated while working inside, pay

attention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open.

Remove guards only when necessary to perform maintenance, and replace them when the maintenance requiring their removal is complete.

Use suitable tools and clothes

.

Do not modify the components if not authorized.

- See pag. M1.1 -

HOT surface can hurt you

ENGINE and ALTERNATOR

PLEASE REFER TO THE SPECIFIC MANUALS

PROVIDED.

NOTE

By maintenance at care of the utilizer we intend all the operatios concerning the verification of mechanical parts, electrical parts and of the fluids subject to use or consumption during the normal operation of the machine.

For what concerns the fluids we must consider as maintenance even the periodical change and or the refills eventually necessary.

Maintenance operations also include machine cleaning operations when carried out on a periodic basis outside of the normal work cycle.

The repairs cannot be considered among the maintenance activities, i.e. the replacement of parts subject 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.

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 (frequent stops and starts, dusty environment, cold weather,extended periods of no load operation, fuel with over 0.5% sulphur content) do maintenance more frequently.

BATTERY WITHOUT MAINTENANCE

DO NOT OPEN THE BATTERY

The battery is charged automatically from the battery charger circuit suppplied with the engine.

Check the state of the battery from the colour of the warning light which is in the upper part.

!

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.

- Green colour: battery OK

- Black colour: battery to be recharged

- White colour: battery to be replaced

!

NOTE

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.

MAINTENANCE GE

M

43.1

© MOSA 1.0-09/05

!

ATTENTION

Maintenance operations on the electricity-generating group prearranged for automatic operation must be carried out with the panel in RESET mode.

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 prolonged periods of inactivity.

MAINTENANCE GENERATING SET WITH AUTOMATIC BOARD

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

EVERY

WEEK

NO-LOAD

X

X

EVERY MONTH

AND/OR AFTER

INTERVENTION ON

LOAD

WITH LOAD

X

X

X

EVERY YEAR

X

Carry out motor oil change at least once a year, even if the requested number of hours has not been attained.

STORAGE

© MOSA 1.0-06/00

In case the machine should not be used for more than 30 days, make sure that the room in which it is stored presents a suitable shelter from heat sources, weather changes or anything which can cause rust, corrosion or damages to the machine.

Have qualified personnel prepare the machine for storage.

GASOLINE ENGINE

Start the engine: lt 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.

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_

M

45

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.

CUST OFF

© MOSA 1.0-03/00

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.

GE_, MS_, TS_

M

46

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 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.

In case of necessity for first aid and fire prevention, see page M2.5.

!

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 dispositions in force in the place.

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.

Technical data GE 275 VPS - VPSX

M

51.1

© MOSA REV.0-07/06

The generating set GE 275 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 275 VPS GE 275 VPSX

GENERATOR

Power (*stand by)

Power (**P.R.P.)

Active power (*stand by)

Active power (**P.R.P.)

Frequency

Cos ϕϕϕϕϕ

ALTERNATOR type

275 kVA / 400 V / 397 A

250 kVA / 400 V / 361 A

220 kW / 400 V / 318 A

220 kW / 400 V / 289 A

50 Hz

0.8

three-phase, synchronous, Self-excited, self-regulated with AVR

H

Insulation class

ENGINE

Make

Model

Type

Displacement

Cylinders

Power (*stand by)

Power (**P.R.P.)

Speed

Fuel consumption

Cooling system

Cooling system capacity

Engine oil capacity

Starter

Fuel

GENERAL SPECIFICATIONS

VOLVO PENTA

TAD740GE

Water to air intercooler

7280 cm

6 on line

Diesel

3

242 kW ( 325 CV)

220 kW (295 CV)

1500 rpm

200 g/kWh

Liquid

37 l

24 l

Electric

Battery

Tank capacity

Running time (75%)

Protection

Dimensions / max. on base Lxwxh (mm) *

Weight on base

Noise level

3000 Kg

96 LWA (71 db(A))

* Dimensions and weight are inclusive of all parts

24V (2x12V - 100Ah)

250 l

6.5 h

IP 44

4000x1300x1950

3050 Kg

93 LWA (68 db(A))

Declared power according to ISO 3046/1 (temperature 25°C, 30% relative hummidity, 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. It’s admitted overload of 10% each hour every 12 h.

OUTPUT

In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.

For possible modifications or changes to be brought on the engines, with climate conditions different from those above mentioned, please call our Assistance Authorized Centers.

ACOUSTIC POWER LEVEL

The machine respects the noise limits, expressed in sound power, given in the a.m. directives.

These limits can be used to judge the sound level produced on site.

For example: the sound power level of 100 LWA.

The sound pressure (noise produced) at 7 meters distance is about 75dBA (the limit value less 25).

To calculate the sound level at other distances use this formula: dBAx = dBAy + 10 log ry² rx²

At 4 meters the noise level becomes: 75 dBA + 10 log = 80 dBA

© MOSA REV.0-07/06

Dimensioni

Dimensions

Dimensions

D

E

NL

Abmessungen

Dimensiones GE 275 VPS - VPSX

M

53

ELECTRICAL SYSTEM LEGENDE

© MOSA 1.4-02/06

A: Alternator

B: Wire connection unit

C: Capacitor

D: G.F.I.

E: Welding PCB transformer

F: Fuse

G: 400V 3-phase socket

H: 230V 1phase socket

I: 110V 1-phase socket

L: Socket warning light

M: Hour-counter

N: Voltmeter

P: Welding arc regulator

Q: 230V 3-phase socket

R: Welding control PCB

S: Welding current ammeter

T: Welding current regulator

U: Current transformer

V: Welding voltage voltmeter

Z: Welding sockets

X: Shunt

W: D.C. inductor

Y: Welding diode bridge

A3: Insulation moitoring

B3: E.A.S. connector

C3: E.A.S. PCB

D3: Booster socket

E3: Open circuit voltage switch

F3: Stop push-button

G3: Ignition coil

H3: Spark plug

I3: Range switch

L3: Oil shut-down button

M3: Battery charge diode

N3: Relay

O3: Resistor

P3: Sparkler reactor

Q3: Output power unit

R3: Electric siren

S3: E.P.4 engine protection

T3: Engine control PCB

U3: R.P.M. electronic regulator

V3: PTO HI control PCB

Z3: PTO HI 20 l/min push-button

W3: PTO HI 30 l/min push-button

X3: PTO HI reset push-button

Y3: PTO HI 20 l/min indicator

A1: Arc striking resistor

B1: Arc striking circuit

C1: 110V D.C./48V D.C. diode bridge

D1: E.P.1 engine protection

E1: Engine stop solenoid

F1: Acceleration solenoid

G1: Fuel level transmitter

H1: Oil or water thermostat

I1: 48V D.C. socket

L1: Oil pressure switch

M1: Fuel warning light

N1: Battery charge warning light

O1: Oil pressure warning light

P1: Fuse

Q1: Starter key

R1: Starter motor

S1: Battery

T1: Battery charge alternator

U1: Battery charge voltage regulator

V1: Solenoid valve control PCBT

Z1: Solenoid valve

W1: Remote control switch

X1: Remote control and/or wire feeder socket

Y1: Remote control plug

A4: PTO HI 30 l/min indicator

B4: PTO HI reset indicator

C4: PTO HI 20 l/min solenoid valve

D4: PTO HI 30 l/ min solenoid valve

E4: Hydraulic oil pressure switch

F4: Hycraulic oil level gauge

G4: Preheating glow plugs

H4: Preheating gearbox

I4: Preheating indicator

L4: R.C. filter

M4: Heater with thermostat

N4: Choke solenoid

O4: Step relay

P4: Circuit breaker

Q4: Battery charge sockets

R4: Sensor, cooling liquid temperature

S4: Sensor, air filter clogging

T4: Warning light, air filter clogging

U4: Polarity inverter remote control

V4: Polarity inverter switch

Z4: Transformer 230/48V

W4: Diode bridge, polarity change

X4: Base current diode bridge

Y4: PCB control unit, polarity inverter

A2: Remote control welding regulator

B2: E.P.2 engine protection

C2: Fuel level gauge

D2: Ammeter

E2: Frequency meter

F2: Battery charge trasformer

G2: Battery charge PCB

H2: Voltage selector switch

I2: 48V a.c. socket

L2: Thermal relay

M2: Contactor

N2: G.F.I. and circuit breaker

O2: 42V EEC socket

P2: G.F.I. resistor

Q2: T.E.P. engine protection

R2: Solenoid control PCBT

S2: Oil level transmitter

T2: Engine stop push-button T.C.1

U2: Engine start push-buttonT.C.1

V2: 24V c.a. socket

Z2: Thermal magnetic circuit breaker

W2: S.C.R. protection unit

X2: Remote control socket

Y2: Remote control plug

A5: Base current switch

B5: Auxiliary push-button ON/OFF

C5: Accelerator electronic control

D5: Actuator

E5: Pick-up

F5: Warning light, high temperature

G5: Commutator auxiliary power

H5: 24V diode bridge

I5: Y/s commutator

L5: Emergency stop button

M5: Engine protection EP5

N5: Pre-heat push-button

O5: Accelerator solenoid PCB

P5: Oil pressure switch

Q5: Water temperature switch

R5: Water heater

S5: Engine connector 24 poles

T5: Electronic GFI relais

U5: Release coil, circuit breaker

V5: Oil pressure indicator

Z5: Water temperature indicator

W5: Battery voltmeter

X5: Contactor, polarity change

Y5: Commutator/switch, series/parallel

GE_, MS_, TS_

M

60

A6: Commutator/switch

B6: Key switch, on/off

C6: QEA control unit

D6: Connector, PAC

E6: Frequency rpm regulator

F6: Arc-Force selector

G6: Device starting motor

H6: Fuel electro pump 12V c.c.

I6: Start Local/Remote selector

L6: Choke button

M6: Switch CC/CV

N6: Connector – wire feeder

O6: 420V/110V 3-phase transformer

P6: Switch IDLE/RUN

Q6: Hz/V/A analogic instrument

R6: EMC filter

S6: Wire feeder supply switch

T6: Wire feeder socket

U6: DSP chopper PCB

V6: Power chopper supply PCB

Z6: Switch and leds PCB

W6: Hall sensor

X6: Water heather indicator

Y6: Battery charge indicator

A7: Transfer pump selector AUT-0-MAN

B7: Fuel transfer pump

C7: „GECO“ generating set test

D7: Flooting with level switches

E7: Voltmeter regulator

F7: WELD/AUX switch

G7: Reactor, 3-phase

H7: Switch disconnector

I7: Solenoid stop timer

L7: "VODIA" connector

M7: "F" EDC4 connector

N7: OFF-ON-DIAGN. selector

O7: DIAGNOSTIC push-button

P7: DIAGNOSTIC indicator

Q7: Welding selector mode

R7: R.C. net

S7: 230V 1-phase plug

T7: V/Hz analogic instrument

U7: Engine protection EP6

V7: G.F.I. relay supply switch

Z7: Radio remote control receiver

W7: Radio remote control trasnsmitter

X7: Isometer test push-button

Y7: Remote start socket

S8:

T8:

U8:

V8:

Z8:

W8:

X8:

Y8:

I8:

L8:

M8:

N8:

O8:

P8:

Q8:

R8:

A8: Transfer fuel pump control

B8: Ammeter selector switch

C8:

D8:

E8:

F8:

G8: Polarity inverter two way switch

H8:

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE275 VPS - VPSX

M

61.1

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPSX

EP6 VERSION

M

61.2

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPS - VPSX

M

61.3

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPSX

EP6 VERSION

M

61.4

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 225 - 275 VPS - VPSX

M

61.5

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPSX

EP6 VERSION

M

61.6

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPS - VPSX

M

61.7

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPSX

EP6 VERSION

M

61.8

© MOSA REV.0-07/06

Schema elettrico

Electric diagram

Schemas electriques

GE 275 VPSX

EP6 VERSION

M

61.9

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