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1 2 0 9
GE 55 PS
GE 55 PMS
740569003 - GB
USE AND MAINTENANCE MANUAL
SPARE PARTS CATALOG
04/05/06 74056M00 preparato da UPT approvato da DITE
DESCRIPTION OF THE MACHINE
© MOSA REV.1-12/09
Main Characteristics of the unit:
• Three-phase electric power (max) 40.8 kW / 400 V / 50 Hz.
• Perkins Diesel engine 1103C - 33TG3
• Brushless synchronous alternator
• Tank of 65l with autonomy of 8.1 h
• Dimensions / weight, 2030x870x1130 / 1000 Kg (PS) - 940 Kg (PMS)
• Noise level at 7m 72dBA
• Prepared for automatic start unit.
• Prepared for remote start/stop.
GE 55 PS - PMS
M
0
EMERGENCY
STOP
EAS
CONNECTOR
CONNECTOR FOR
REMOTE START
FILTER
BATTERY
The unit is composed of: a structured base which includes a tank, an engine/alternator unit fixed on the base by 3 elastic dampers, a roll-bar, with hook for an easy and sure lifting, a chest hinged to the roll-bar for a quick access to the engine, a front panel covered with a lid where are mounted the sockets , the protections and the measure instruments. The battery and the engine air filter are protected by a plate hinged to roll-bar and fixed to the structure with 2 rapid block screws with a wrench given as equipment not to be lost.
© MOSA REV.3-02/09
Quality system
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.1-10/07
INDEX
M 01 QUALITY SYSTEM
M 1.01
COPYRIGHT
M 1.1
NOTES
M 1.4
CE MARK
M 1.5
TECHNICAL DATA
M 1.6
TECHNICAL DATA ENGINE DRIVEN WELDER
M 2-2.1
SYMBOLS AND SAFETY PRECAUTIONS
M 2.5... INSTALLATION AND ADVICE BEFORE USE
M 2.6
INSTALLATIONS AND ADVICE
M 2.7
INSTALLATION
M 3 PACKING
M 4...
TRANSPORT AND DISPLACEMENTS
M 6...
ASSEMBLY: CT........
M 20 SETTING-UP THE UNIT (DIESEL ENGINE)
M 21
M 22
ENGINE STARTING AND USE (DIESEL ENGINE)
STOPPING THE ENGINE (DIESEL ENGINE)
M 25
M 26
M 27
M 30
M 31
M 34
M 35
M 36
SETTING-UP THE UNIT (GASOLINE ENGINE)
STARTING THE ENGINE (GASOLINE ENGINE)
STOPPING THE ENGINE (GASOLINE ENGINE)
CONTROLS LEGEND
CONTROLS
USE AS A WELDER
USE AS AN ENGINE STARTER
USE AS A BATTERY CHARGE
M 37...
USE AS A GENERATOR
M 38...
USE OF THE REMOTE CONTROL
M 39...
USE OF THE ENGINE PROTECTION
M 40...
TROUBLE SHOOTING
M 43...
MAINTENANCE
M 45 STORAGE
M 46
M 53
CAST OFF
DIMENSIONS
M 55
M 60
RECOMMENDED ELECTRODES
ELECTRICAL SYSTEM LEGENDE
M 61...
ELECTRICAL SYSTEM
R 1
......
K...
SPARE PARTS LIST
SPARE PARTS
ACCESSORIES
GE_, MS_, TS_, EAS_
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).
©
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.
CE MARK
M
1.4
© MOSA REV.4-10/07
Any of our product is labelled with CE marking attesting its conformity to appliable directives and also the fulfillment of safety requirements of the product itself; the list of these directives is part of the declaration of conformity included in any machine standard equipment.
Here below the adopted symbol:
CE marking is clearly readable and unerasable and it can be either part of the data-plate (A) or placed as a sticker near the data-plate (B)
A
B
Furthermore, on each model it is shown the noise level value; the symbol used is the following:
The indication is shown in a clear, readable and indeleble way on a sticker.
GE 55 PS - PMS
M
1.5
© MOSA REV.1-12/09
Technical data
The generating set GE 55 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
GENERATOR
*Stand-by three-phase power
**P.R.P. three-phase power
**P.R.P. single-phase power
Frequence
Cos
ϕϕϕϕϕ
ALTERNATOR
Type
Insulation class
MOTOR
Make / Model
Type / Cooling system
Cylinder / Displacement
Stand-by net power
P.R.P. net power
Speed
Fuel consumption (75% of P.R.P.)
Engine and filter oil capacity
Starter
GENERAL SPECIFICATION
Battery
Fuel tank capacity
Running time (75% of P.R.P.)
Protection
Dimensions max. on base Lxwxh *
Weight on base *
Guaranteed acoustic power LwA (pressure LpA)
Measured acoustic power LwA (pressure LpA)
* Dimensions and weight are inclusive of all parts.
GE 55 PS
1000 Kg
51 kVA (40.8 kW)/ 400 V / 73.6 A
46 kVA (36.8 kW)/ 400 V / 66.4 A
17 kVA / 230 V / 73.9 A
50 Hz
0.8
Self-excited, self-regulated, brushless synchronous, three-phase
H
Perkins / 1103C - 33TG3
Diesel 4-Stroke / Water
3 / 3.3 l (3300 cm 3 )
45.6 kW (62 HP)
40.9 kW (55.6 HP)
1500 rpm
8 l/h
7.9 l
Electric
GE 55 PMS
12V - 100 Ah
65 l
8.1 h
IP 23
2030x870x1130
940 Kg
97 dB(A) (72 dB(A) @ 7 m)
97 dB(A) (72 dB(A) @ 7 m)
2000 / 14 / CE
OUTPUT
Declared power according to ISO 8528-1 (temperature 25°C, 30% relative humidity, altitude 100 m above sea level).
(*Stand-by) = maximum available power for use at variable loads for a yearly number of hours limited at 500 h. No overload is admitted.
(**Prime power P.R.P.) = maximum available power for use at variable loads for a yearly illimited number of hours. The average power to be taken during a period of 24 h must not be over 80% of the P.R.P.
It’s admitted overload of 10% each hour every 12 h.
In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.
ACOUSTIC POWER LEVEL
ATTENTION: The concrete risk due to the machine depends on the conditions in which it is used. Therefore, it is up to the enduser and under his direct responsibility to make a correct evaluation of the same risk and to adopt specific precautions (for instance, adopting a I.P.D. -Individual Protection Device)
Acoustic Noise Level (LWA) - Measure Unit dB(A): it stands for acoustic noise released in a certain delay of time. This is not submitted to the distance of measurement.
Acoustic Pressure (Lp) - Measure Unit dB(A): it measures the pressure originated by sound waves emission. Its value changes in proportion to the distance of measurement.
The here below table shows examples of acoustic pressure (Lp) at different distances from a machine with Acoustic Noise
Level (LWA) of 95 dB(A)
Lp a 1 meter = 95 dB(A) - 8 dB(A) = 87 dB(A)
Lp a 4 meters = 95 dB(A) - 20 dB(A) = 75 dB(A)
Lp a 7 meters = 95 dB(A) - 25 dB(A) = 70 dB(A)
Lp a 10 meters = 95 dB(A) - 28 dB(A) = 67 dB(A) according to 2000/14/CE directive.
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
WARNING
This heading warns of situations which could result in injury for persons or damage to things.
- 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.
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.
IMPORTANT
WARNING
Situations of danger - no harm to persons or things
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.
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
Static electricity can demage the parts on the circuit.
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
M
2.6
© MOSA REV.1-06/07
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
DI SCARICO
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
ATTENTION
For a safer use from the operator DO NOT fit the machine in locations with high risk of flood.
Please do not use the machine in weather conditions which are beyond IP protection shown both in the data plate and on page named "technical data" in this same manual.
Maximum leaning of the machine (in case of dislevel)
© MOSA REV.0-05/06
Installazione
Installation
Installation
Luftzirculation
GE 55 PS - PMS
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 GE_, MS_, TS_
M
4
© 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.
LIFT ONLY THE MACHINE
DO NOT LIFT THE MACHINE AND TRAILER
DANGER: LIFTING EYE IS NOT DESIGNED TO SUPPORT
ADDED WEIGHT OF ROAD TOW TRAILER
ASSEMBLY
CTL 35 -45 - 50 - 95 M
6.8
© MOSA 1.1-04/06
ATTENTION
The CTL accessory cannot be removed from the machine and used separately (actioned manually or following vehicles) for the transport of loads or anyway for used different from the machine movements.
TRAILERS
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a maximum speed of 40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements by national and foreign traffic norms.
Nota: Lift the machine and assemble the parts as shown in the drawing
CTL 35-50
CTL 45
COMANDS
CTL 95
For assembling the generating set on the trolley CTL 35-45 -
50 - 95 please keep to following instructions:
1) - Lift thr generating set (by means of suitable hook)
6) - Assemble on the machine the towbar (5) complete of foot with the M10x20 screws,nuts and washers.
7) - Assemble the axle (7) to the base of the machine with the M10x20 screws and relative washers (two per part) so that their supports coincide.
8) - Insert the wheel (9) on the axle then twist the selfblocking nut (8).
9) - Pump the tyre (9) bringing the pressure to 4 atms for the CTL 35-45-50 and 5/6 for the CTL 95.
10) - Lower the machine to the ground and place the parking foot definitively (regulating at the best height).
7
9
ATTENTION
Do not substituite the original tires with other types.
5
CTL 35-50
8
5
CTL 45-95
Set-up for operation TS_,DSP_,GE
Water cooled systems
M
20
© MOSA 1.1-09/05
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.
LUBRICANT
RECOMMENDED OIL
MOSA recommends selecting AGIP engine oil.
Refer to the label on the motor for the recommended products.
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
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.
© MOSA
Set-up for operation
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.0-02/06
Check daily
START AND STOP
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 3 different modes:
1) Start with EP6 key (Engine Control)
Put the “Local/Remote” selector on Local. Turn the key on “ON”, the EP6 display shows only on the machines with mounted glow plugs for 5 secs, the symbol “UUUU”, then the message “Sta” appears the engine can be started, for which turn the key on “start” and start the engine.
On the display the word “Sta” remains for about
20 secs then automatically disappears; the engine
must be started within 20 secs, otherwise the
EP6 blocks the starting and on the display the word “fail” appears. Turning the key on “OFF” the
EP6 is reset and a new starting cycle can be fixed.
Stop: it is COMPULSORY to disconnect the load first, then to stop the engine turn the key on “OFF”.
GE 14000 YS/GS
GE 20-35-55-65 P
GE 85-115-145-165
M
21
3) Start with Automatic start unit (EAS)
Put the “Local/Remote” selector on Remote.
Connect the EAS to unit.
The EAS controls the starting as well as the stop of the engine.
Follow attentively the instructions reported in the
EAS manual. In these conditions the EP6 has the only function to measure the electric values, hourmeter, etc.
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 “Local/Remote” selector on Local.
Connect TCM35 to the plug on the front panel and put the switch on “0”.
Turn the key on ON in the EP6 (Engine Control), wait for the various signals to go out then press the button “AUTO” in the EP6 until the led “AUTO” flashes.
Shift the switch on “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.
CONTROLS LEGENDE
© MOSA REV.1-10/07
15
16
17
19
4A
9
10
12
Hydraulic oil level light
Welding socket ( + )
Welding socket ( - )
Earth terminal
A.C. socket
Accelerator lever
Feed pump
48V D.C. socket
22
23
Engine air filter
Oil level dipstick
24 Engine oil reservoir cap
24A Hydraulic oil reservoir cap
24B Water filling cap
25 Fuel prefilter
Fuel tank cap 26
27
28
29
30
31
Muffler
Stop control
Engine protection cover
Engine cooling/alternator fan belt
Oil drain tap
31A Hydraulic oil drain tap
31B Water drain tap
31C Exhaust tap for tank fuel
32
33
Button
Start button
34 Booster socket 12V
34A Booster socket 24V
35
36
37
42
Battery charge fuse
Space for remote control
Remote control
Space for E.A.S.
42A Space for PAC
47 Fuel pump
Electric start socket 49
54
55
Reset button PTO HI
Quick coupling m. PTO HI
55A Quick coupling f. PTO HI
56
59
Hydraulic oil filter
Battery charger thermal switch
59A Engine thermal switch
59B Aux current thermal switch
59C Supply thermal switch wire feeder-
42V
59D Pre-heater (spark plug) thermal switch
59E Supply thermal switch oil/water heather
59F Electropump thermal switch
63
66
No load voltage control
Choke control
67A Auxiliary / welding current control
68 Cellulosic electrodes control
69A Voltmeter relay
70
71
72
73
74
75
Warning lights
Selecting knob
76
79
86 Selector
86A Setting confirmation
87
88
A3
Load commut. push button
Starting push button
Operating mode selector
Power on warning light
Display
Wire connection unit
Fuel valve
Oil syringe
Insulation monitoring
U4
U5
U7
V
T5
T7
U
U3
V4
V5
W1
W3
S6
S7
T
T4
R3
S
S1
S3
Q1
Q3
Q4
Q7
N5
N6
O1
P
L6
M
M1
M2
I6
I8
L
L5
M5
M6
N
N1
N2
I2
I3
I4
I5
G1
H2
H6
H8
F
F3
F5
F6
D
D1
D2
E2
B5
C2
C3
C6
A4
B2
B3
B4
Button indicating light 30 l/1' PTO HI
Engine control unit EP2
E.A.S. connector
Exclusion indicating light PTO HI
Auxiliary current push button
Fuel level light
E.A.S. PCB
Control unit for generating sets QEA
Ground fault interrupter ( 30 mA )
Engine control unit and economiser EP1
Ammeter
Frequency meter
Fuse
Stop switch
Warning light, high temperature
Arc-Force selector
Fuel level transmitter
Voltage commutator
Fuel electro pump
Engine control unit EP7
48V A.C. socket
Welding scale switch
Preheating indicator
Y/▲ switch
Start Local/Remote selector
AUTOIDLE switch
A.C. output indicator
Emergency button
Choke button
Hour counter
Warning level light
Contactor
Engine control unit EP5
CC/CV switch
Voltmeter
Battery charge warning light
Thermal-magnetic circuit breaker/
Ground fault interrupter
Pre-heat push-button
Connector - wire feader
Oil pressure warning light/Oil alert
Welding arc regulator
Starter key
Derivation box
Battery charge sockets
Welding selector mode
Siren
Welding ammeter
Battery
Engine control unit EP4
Wire feeder supply switch
Plug 230V singlephase
Welding current regulator
Dirty air filter warning light/indicator
Earth leakage relay
Analogic instrument V/Hz
Current trasformer
R.P.M. adjuster
Polarity inverter remote control
Relase coil
Engine control unit EP6
Welding voltage voltmeter
Polarity inverter control
Oil pressure indicator
Remote control switch
Selection push button 30 l/1' PTO HI
M
30
Y3
Y5
Z2
Z3
Z5
W5 Battery voltmeter
X1 Remote control socket
Button indicating light 20 l/1' PTO HI
Commutator/switch, serial/parallel
Thermal-magnetic circuit breaker
Selection push button 20 l/1' PTO HI
Water temperature indicator
© MOSA REV.0-05/06
Comandi
Controls
Commandes
Bedienelemente
GE 55 PS - PMS
D2
V5
(SR)
Z5
(SR)
C2 H2
V7
D
Z2
15
M
31
59B 59D
59A I6
L5
B3 X1
15
24B
12
22
R3
S1
S7
(SR)
59E
(SR)
27
23-24
26
G1
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).
GE_
Diesel engine
M
37
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.
GE_
Diesel engine
M
37.
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
RESET
I°
A tx10 x1 x10
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
I° tx10 x1
A x10
RESET x0.1I°
0.1
0.2
TEST
T5.4
0.3
0.4
T5.1
ON TRIP
0.02
0.5
t (s)
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.
GE_
Diesel engine
M
37.
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.
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
4.1 Operating Messages
M39.12
M39.12
M39.12
M39.12
M39.12
M39.12
M39.12.1
M39.12.1
5.0 LEDs for visual indication
5.1 LEDs and Display Test
6.0 Parameters and Settings
7.0 Remote Start
M39.12.1
M39.12.1
M39.12.1
M39.12.4
8.0 Safety
9.0 Automatic Periodic Test
M39.12.4
M39.12.4
10.0 Front Panel Description 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-]
[. . . .]
[rESt]
[tESt]
[CAL]
Glow-plugs timing
Voltage out of range
Start prompt
Starting by key switch
Rest timing
Automatic Test
Calibration
[Pro-]
[rEAd]
Programming
Parameter reading
[StOP]
Stopping cycle
[MM.SS]
Remote Start or Remote Stop cycle
EP6 ENGINE PROTECTION
5.0 LEDs for visual indication
The EP6 features two LEDs (see section 10.0) to indicate the following 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
M
39.12.
1
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 seconds Maximum 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
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
4 digits DISPLAY
[UP DOWN]
Button
Ideograms
Button
[F1]
Green LED engine on
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
Front view
Closing cover
Rear view
Recommended hole dimensions:
91mm (+/- 0.5) x 91mm (+/- 0.5)
Rear cover
Cables outlet
Troubleshooting
© MOSA REV.3-07/06
Problem
The motor does not start up
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)
Black smoke
White smoke
Low oil pressure
High temperature
4) Engine control unit or starting key faulty.
5) Battery low
The motor does not accelerate. Inconstant speed.
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.
Too little power provided by motor.
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)
GE
Diesel engine
Solution
M
40.2
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 1) Voltage switch in position 0
No-load voltage too low or too high
1) Incorrect motor running speed
2) Voltage regulating device (where it is assembled) defective or requires calibration
3) Alternator defective
Corrected no-load voltage too low with load
Unstable tension
Troubleshooting
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
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 due to overload
Possible cause
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.
© MOSA REV.1-05/08
Dimensioni
Dimensions
Dimensions
Abmessungen
Dimensiones GE 35PS-PSX - 55 PS-PMS
DSP 600 PSX
M
53
175
ø13 n°4 fori
1640
2030
57.5
ø13
735
870
ELECTRICAL SYSTEM LEGENDE
© MOSA REV.7-10/09
C
D
E
A
B
F
G
: Alternator
: Wire connection unit
: Capacitor
: G.F.I.
: Welding PCB transformer
: Fuse
: 400V 3-phase socket
I
H
L
: 230V 1phase socket
: 110V 1-phase socket
: Socket warning light
M : Hour-counter
N : Voltmeter
P
Q
R
S
T
: Welding arc regulator
: 230V 3-phase socket
: Welding control PCB
: Welding current ammeter
: Welding current regulator
U
V
Z
: Current transformer
: Welding voltage voltmeter
: 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
D 3 : Booster socket
E 3 : Open circuit voltage switch
F3 : Stop push-button
G 3 : Ignition coil
H 3 : Spark plug
I3 : Range switch
L 3 : Oil shut-down button
M 3 : Battery charge diode
N 3 : Relay
O 3 : Resistor
P3 : Sparkler reactor
Q 3 : Output power unit
R 3 : Electric siren
S3 : E.P.4 engine protection
T 3 : Engine control PCB
U 3 : R.P.M. electronic regulator
V3 : PTO HI control PCB
Z 3 : 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
D 1 : E.P.1 engine protection
E 1 : Engine stop solenoid
F1 : Acceleration solenoid
G 1 : Fuel level transmitter
H 1 : Oil or water thermostat
I1 : 48V D.C. socket
L 1 : Oil pressure switch
M 1 : Fuel warning light
N 1 : Battery charge warning light
O 1 : Oil pressure warning light
P1 : Fuse
Q 1 : Starter key
R 1 : Starter motor
S1 : Battery
T 1 : Battery charge alternator
U 1 : Battery charge voltage regulator
V1 : Solenoid valve control PCBT
Z 1 : 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
D 4 : PTO HI 30 l/ min solenoid valve
E 4 : Hydraulic oil pressure switch
F4 : Hycraulic oil level gauge
G 4 : Preheating glow plugs
H 4 : Preheating gearbox
I4 : Preheating indicator
L 4 : R.C. filter
M 4 : Heater with thermostat
N 4 : Choke solenoid
O 4 : Step relay
P4 : Circuit breaker
Q 4 : Battery charge sockets
R 4 : Sensor, cooling liquid temperature
S4 : Sensor, air filter clogging
T 4 : Warning light, air filter clogging
U 4 : Polarity inverter remote control
V4 : Polarity inverter switch
Z 4 : 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
D 2 : Ammeter
E 2 : Frequency meter
F2 : Battery charge trasformer
G 2 : Battery charge PCB
H 2 : Voltage selector switch
I2 : 48V a.c. socket
L 2 : Thermal relay
M 2 : Contactor
N 2 : G.F.I. and circuit breaker
O 2 : 42V EEC socket
P2 : G.F.I. resistor
Q 2 : T.E.P. engine protection
R 2 : Solenoid control PCBT
S2 : Oil level transmitter
T 2 : Engine stop push-button T.C.1
U 2 : Engine start push-buttonT.C.1
V2 : 24V c.a. socket
Z 2 : 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
D 5 : Actuator
E 5 : Pick-up
F5 : Warning light, high temperature
G 5 : Commutator auxiliary power
H 5 : 24V diode bridge
I5 : Y/s commutator
L 5 : Emergency stop button
M 5 : Engine protection EP5
N 5 : Pre-heat push-button
O 5 : Accelerator solenoid PCB
P5 : Oil pressure switch
Q 5 : Water temperature switch
R 5 : Water heater
S5 : Engine connector 24 poles
T 5 : Electronic GFI relais
U 5 : Release coil, circuit breaker
V5 : Oil pressure indicator
Z 5 : Water temperature indicator
W5 : Battery voltmeter
X5 : Contactor, polarity change
Y5 : Commutator/switch, series/parallel
M
60
A6 : Commutator/switch
B6 : Key switch, on/off
C6 : QEA control unit
D 6 : Connector, PAC
E 6 : Frequency rpm regulator
F6 : Arc-Force selector
G 6 : Device starting motor
H 6 : Fuel electro pump 12V c.c.
I6 : Start Local/Remote selector
L 6 : Choke button
M 6 : Switch CC/CV
N 6 : Connector – wire feeder
O 6 : 420V/110V 3-phase transformer
P6 : Switch IDLE/RUN
Q 6 : Hz/V/A analogic instrument
R 6 : EMC filter
S6 : Wire feeder supply switch
T 6 : Wire feeder socket
U 6 : DSP chopper PCB
V6 : Power chopper supply PCB
Z 6 : 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
D 7 : Flooting with level switches
E 7 : Voltmeter regulator
F7 : WELD/AUX switch
G 7 : Reactor, 3-phase
H 7 : Switch disconnector
I7 : Solenoid stop timer
L 7 : "VODIA" connector
M 7 : "F" EDC4 connector
N 7 : OFF-ON-DIAGN. selector
O 7 : DIAGNOSTIC push-button
P7 : DIAGNOSTIC indicator
Q 7 : Welding selector mode
R 7 : VRD load
S7 : 230V 1-phase plug
T 7 : V/Hz analogic instrument
U 7 : Engine protection EP6
V7 : G.F.I. relay supply switch
Z 7 : Radio remote control receiver
W7 : Radio remote control trasnsmitter
X7 : Isometer test push-button
Y7 : Remote start socket
A8 : Transfer fuel pump control
B8 : Ammeter selector switch
C8 : 400V/230V/115V commutator
D 8 : 50/60 Hz switch
E 8 : Cold start advance with temp. switch
F8 : START/STOP switch
G 8 : Polarity inverter two way switch
H 8 : Engine protection EP7
I8 : AUTOIDLE switch
L 8 : AUTOIDLE PCB
M 8 : A4E2 ECM engine PCB
N 8 : Remote emergency stop connector
O 8 : V/A digital instruments and led VRD PCB
P8 : Water in fuel
Q 8 : Battery disconnect switch
R 8 : Inverter
S8 : Overload led
T 8 : Main IT/TN selector
U 8 : NATO socket 12V
V8 : Diesel pressure switch
Z 8 : Remote control PCB
W8 : Pressure turbo protection
X8 :
Y8 :
© MOSA REV.2-05/08
Schema elettrico
Electric diagram
Schema electriques
Stromlaufplan
Esquema eléctrique GE 35 PS - PSX
GE 55 PS - PMS
M
61.1
7
11
RPM+
1
RPM-
GND
5
13
4
3
2
6
10
30
Vnero/black
+
OPTIONAL: PRH3
1 4
nero/black nero/black
© MOSA REV.0-10/05
Schema elettrico
Electric diagram
Schema electriques
Stromlaufplan
Esquema eléctrique GE 55 PS - PMS
M
61.2
© MOSA REV.0-03/06
Schema elettrico
Electric diagram
Schema electriques
Stromlaufplan
Esquema eléctrique GE 35 PS - PSX
GE 55 PS - PMS
M
61.4
© MOSA REV.0-03/06
Schema elettrico
Electric diagram
Schema electriques
Stromlaufplan
Esquema eléctrique
GE 35 PS - PSX
GE 55 PS - PMS
GE 85-115 PSX - PMSX
M
61.5
ANT.
12V
24V
0
ANTENNA AERIAL
(RED)
5
V-
OUT1
(BLACK)
7
© MOSA REV.0-03/06
Schema elettrico
Electric diagram
Schema electriques
Stromlaufplan
Esquema eléctrique
GE 35 PS - PSX
GE 55 PS - PMS
GE 85-115 PSX - PMSX
M
61.6
CH.C
CH.D
CH.B
CH.A
ANT.
12V
24V
0
OFF
ON
12
SPARE PARTS LIST
R
1
© MOSA 1.0-03/00
MOSA guarantees that any request for spare parts will be satisfied.
To keep the machine in full working order, when replacement of MOSA spare parts is required, always ask for genuine parts only.
The requested data are to be found on the data plate located on the machine structure, quite visible and easy to consult.
✹
When ordering the spare parts, it is recommended to indicate:
1) ✹ serial number
2) ✹ model of welder and/or generating set
3) ◆ n. table
4) ◆ n. position
5) quantity
V.le Europa,59 - 20090 CUSAGO (MI) ITALY
Tel. +39-02 90352.1 - fax +39-02 90390466
TYPE
SERIAL N°
0987654321
TAVOLA RICAMBI - SPARE PARTS - PIECES DE RECHANGE - ERSATZTEILE
EA
1
1-3 13 18 17 16 20-21-22 12
EA
1
12
3
EA
1
4
12
11
HOURMETER h
0
0
RS
ST
TR
V
100
200
300
500
Hz
55
60
50
65
A
10
15
20
25
125
*
OFF
ON
START 0
19
15
2
8
NEUTROCOLLEGATOAMASSA
NEUTROCONECTADOAMASA
NEUTRALBONDEDTOFRAME
NEUTRERACCORDEAUBATI
NULLEITERAUFMASSE
NULVERBONDENMETMASSA
14
21-22-23
*
VE
4-5-6
ABBREVIATIONS AND SYMBOLS:
(EV) When ordering, specify the engine type and the auxiliary voltage
(ER) Engine with recoil starter only
(ES) Engine with electric starter only
(VE) E.A.S version only.
(QM) When ordering, specify the length in meters
(VS) Special version only
(SR) By request only
© MOSA REV.1-12/09
Ricambi
Spare parts
Piéces de rechange
Ersatzteile
Tabla de recambios
2
GE 55 PS - PMS
3
IL
25
1
4
5
6
6a
7
8
Pos.
6
6a
4
5
1
2
3
7
8
8
© MOSA
Pos.
6a
7
5
6
8
8
3
4
1
2
REV.1-12/09
Tavola ricambi
Spare parts table
Table piéces de rechange
Ersatzteile
Tabla de recambios
Rev. Cod.
Descr.
740568066 CORNICE PER RADIATORE
325417007 PANNELLO POST.SCATOLA ELETTR.
740567048 FIANCATA DX SCATOLA ELETTRICA
325417001 PANNELLO ANT. SCATOLA ELETTR.
740553101 TRAVERSA SUPP. ALTERNATORE
740553100 ALTERNATORE STAMFORD
840573100 ALTERNATORE MARELLI
325417049 FIANCATA SX SCATOLA ELETTRICA
740552200 MOTORE PERKINS 1103A-33TG1
840562200 MOTORE PERKINS 1103C-33TG3
Note
GE 55 PS - PMS
Fino a REV.0-05/06 Del.05/08-16/01/08
Da REV.1-12/09 Del.05/08-16/01/08
IL
25.1
Rev. Cod.
Descr.
740568066 FRAME FOR RADIATOR
325417007 BACK PANEL ELECTRIC BOX
740567048 RIGHT COVER ELECTRIC BOX
325417001 FRONT PANEL ELECTRIC BOX
740553101 ALTERNATOR SUPPORT BRACKET
740553100 ALTERNATOR STAMFORD
840573100 ALTERNATOR MARELLI
325417049 LEFT COVER ELECTRIC BOX
740552200 ENGINE PERKINS 1103A-33TG1
840562200 ENGINE PERKINS 1103C-33TG3
Note
Up to REV.0-05/06 Del.05/08-16/01/08
From REV.1-12/09 Del.05/08-16/01/08
© MOSA REV.1-12/09
1
Ricambi
Spare parts
Piéces de rechange
2 32 3
Ersatzteile
Tabla de recambios
4
5
GE 55 PS - PMS
(SR)
36
(SR)
37
(SR)
38
33
Kit MG4
(SR)
6
IL
26
7
34
(SR)
35
(SR)
15
17
16
14 13 12 11 10 9 8
18 19 20 21
22
23 24 25
31
27
30
26
28
29
27
28
29
30
23
24
25
26
19
20
21
22
15
16
17
18
35
36
37
38
31
32
33
34
11
12
13
14
7
8
9
10
5
6
3
4
Pos.
1
2
© MOSA REV.1-12/09
Tavola ricambi
Spare parts table
Table piéces de rechange
Ersatzteile
Tabla de recambios
GE 55 PS - PMS
IL
26.1
Cod.
Descr.
Note
325257305 AMPEROMETRO / AMPEROMETER
155307107 DISGIUNTORE TERMICO 15A-250V / THERMAL SWITCH 15A-250V
305019705 INTERR.MAGNET.400V 63A / CIRCUIT BREAKER
305027105 INTERRUTTORE DIFFERENZIALE / GROUNDFAULT INTERRUPTOR (GFI)
1243020 GUIDA PER MORSETTIERA / TERMINAL GUIDE
JK0029770 UNITA’ CONTR. MOTORE (EP6) / ENGINE PROTECTION EP6
102013290 COMMUTATORE / COMMUTATOR
102042740 CAPPUCCIO / CAP
352007109 PROTEZIONE TERMICA 5A / THERMOPROTECTION
306467109 PROTEZIONE TERMICA (C.B.) / THERMOPROTECTION (B.C.)
305717315 COMMUTATORE / COMMUTATOR
325507210 INDICATORE LIVELLO CARBURANTE / FUEL LEVEL GAUGE
307017240 PRESA 220V 16A / EEC SOCKET 16A, 220V 2P+T
317807130 COPERCHIO PROTEZIONE I.D. / COVER PROTECTION
740567020 PANNELLO FRONTALE (superiore) / FRONT PANEL
1240060 MORSETTO 35mmq / TERMINAL 35mmq
1240140 MORSETTO 25mmq / TERMINAL 25mmq
125207306 TRASFORMATORE DI CORRENTE / CURRENT TRANSFORMER
1291190 FUSIBILE / FUSE
107509045 PORTAFUSIBILE / HOLDER, FUSE
740567010 SCATOLA ELETTRICA / ELECTRIC BOX
306479199 RELE’ AVV. ELETTRICO / RELAY, ELECTRIC START
344027270 PRESA CEE 63A 400V 3P+N+T / EEC SOCKET 63A 400V 3P+N+T
744507219 PULSANTE STOP D’EMERGENZA / EMERGENCY PUSH BUTTON STOP
74035C021 GR. CAVI MOTORE / ENGINE CABLES GR.
359257032 COPERCH. CHIUS. FORO SCALDIGLIA
315507215 AVVISATORE ACUSTICO / ACOUSTIC ALARM SYSTEM
105191550 CUSTODIA PER PRESA EAS / BOX, EAS SOCKET
105191560 FRUTTO PRESA CONNETTORE / SOCKET, EAS
105191570 COPERCHIO EAS / EAS COVER
740567205 PANNELLO FRONTALE (inferiore) / FRONT PANEL
201308039 COLONNETTA / CONNECTING CYLINDER
840760094 MG4 KIT TERMO/MANOMETRO / MG4 THERMO/MANOMETER KIT (SR)
744527190 INDIC. PRESSIONE OLIO / OIL PRESSURE INDICATOR (SR)
744527192
842252252
INDIC.TEMP.ACQUA / WATER TEMPERATURE INDICATOR
SENSORE PRESSIONE / PRESSURE SENSOR
840762253 RIDUZIONE / REDUCTION
842252245 SENSORE TEMP. / TEMPERATURE SENSOR
(SR)
(SR - montato sul motore)
(SR - montato sul motore)
(SR - montato sul motore)
© MOSA REV.0-03/06
Ricambi
Spare parts
Piéces de rechange
Ersatzteile
Tabla de recambios GE 55 PS - PMS
IL
27
12
13
7
1
6 5 4 3
2
14
11
2
3
8
9
10
© MOSA
Pos.
13
14
Pos.
9
10
11
12
7
8
5
6
3
4
1
2
9
10
11
12
13
14
7
8
5
6
3
4
1
2
REV.0-05/06
Tavola ricambi
Spare parts table
Table piéces de rechange
Ersatzteile
Tabla de recambios
Rev. Cod.
Descr.
105611550 ANTIVIBRANTE
308102023 GUARNIZIONE
308101262 TAPPO SCARICO SERBATOIO
JJ0062025 RUBINETTO M-F 1/2" G
JJ0062292 NIPPLO OLEODINAMICO 1/2" G
740561050 BASAMENTO
343332038 RONDELLA D12,5x48 SP3
784102069 GUARNIZIONE SCARICO MOTORE
740562050 SILENZIATORE SCARICO (COMPL.)
305232071 GUARNIZIONE PER FLANGIA
105612060 ANTIVIBRANTE (40x100)
740568125 COPERCHIO ISPEZ. DIODI ALTERN.
764409975 SENSORE LIVELLO CARBURANTE(L=225)
740562212 TUBO SCARICO OLIO
Rev. Cod.
Descr.
105611550 VIBRATION DAMPER
308102023 GASKET
308101262 FUEL TANK CAP
JJ0062025 VALVE
JJ0062292 OLEODYNAMIC NIPPLE
740561050 BASE
343332038 WASHER
784102069 GASKET
740562050 EXHAUST MUFFLER
305232071 GASKET X FAN
105612060 VIBRATION DAMPER (40x100)
740568125
DIODES MAINTENANCE COVER
764409975 FUEL LEVEL SENSOR
740562212 EXHAUST OIL PIPE
GE 55 PS - PMS
IL
27.1
9
8
© MOSA REV.0-03/06
Ricambi
Spare parts
Piéces de rechange
1 2
Ersatzteile
Tabla de recambios
3 4
GE 55 PS - PMS
10
IL
28
7
6
17 18
5
19
11
20
23
22
24
15 16
14
12 13
© MOSA
Pos.
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
20
21
22
23
Pos.
16
17
18
19
7
8
5
6
3
4
1
2
9
18
19
20
21
22
23
10
11
12
13
14
15
16
16
17
REV.1-12/09
Tavola ricambi
Spare parts table
Table piéces de rechange
Ersatzteile
Tabla de recambios
GE 55 PS - PMS
Rev. Cod.
Descr.
740561100 ROLL BAR (COMPLETO)
400409154 STAFFA FISSAGGIO BATTERIA
740567015 COPERCHIO SCATOLA ELETTRICA
764409150 BATTERIA 12V 100Ah
740568239 TRAVERSINO SUPP. PARATIA ALTER.
342202026 TAPPO SERBATOIO
740562147 STAFFA FISS.PRE-FILTRO GASOLIO
107300180 CHIUSURA COMPL.A LEVA
740568065 GRIGLIA USCITA ARIA (COMPL.)
740568164 BACINELLA RACCOLTA ACQUA
740568290 PARATIA SUPERIORE ALTERNATORE
305718115 PISTONE SOSTEGNO
740568004 FIANCATA SX CARENAT. ANTERIORE
343339601 MANIGLIA
209718073 TIRANTE
209718070 COPERCHIETTO
766708070 COPERCHIETTO
765007057 CHIAVE PER SERRATURA
740568021 COPERCHIO CARENATURA ANTERIORE
744508140 CERNIERA PER FIANCATA
740568035 CARENATURA POSTERIORE
740568010 FIANCATA DX CARENAT. ANTERIORE
740568100 COPERCHIO FRONTALE
740568270 PERNO PER CERNIERA
Rev. Cod.
Descr.
740561100 ROLL BAR
400409154 BATTERY BRACKET
740567015 ELECTRIC BOX COVER
764409150 BATTERY 12V 100Ah
740568239 SUPPORT ALTERNATOR BRACKET
342202026 CAP, FUEL TANK
740562147 DIESEL PRE-FILTER BRACKET
107300180 LATCH
740568065 OUT AIR GRATE
740568164 WATER TRAY
740568290 ALTERNATOR TOP COVER
305718115 SUPPORT, REAR COVER
740568004 FRONT HAUSING LEFT SIDE
343339601 KNOB
209718073 TIE-ROD
209718070 COVER
766708070 COVER
765007057 ELECTRIC BOX COVER KEY
740568021 COVER HAUSING SIDE
744508140 LATCH
740568035 BACK HAUSING
740568010 FRONT HAUSING RIGHT SIDE
740568100 FRONT COVER
740568270 HINGE PIN
Note
Fino a REV.0-05/06 Del.35/08-18/02/08
Da REV.1-12/09 Del.35/08-18/02/08
Up to REV.0-05/06 Del.35/08-18/02/08
From REV.1-12/09 Del.35/08-18/02/08
IL
28.1
© MOSA 1.0-05/06
CTL 35
740350140
KA
17
Pos. Rev. Cod.
1
3
225100141
305751150
4
5
6
740350142
305751160
325501170
Descr.
GR.TIMONE,PIEDE X TRAINO LENTO
TIMONE
Descr.
KIT SITE TOW
TOW BAR
GR. ASSALE, RUOTE TRAINO LENTO
KIT SITE TOW
ASSALE
AXLE
RUOTA
WHEEL
Note
© MOSA 1.0-06/06
TCM35
930350000
KD
8
Pos. Rev.
Cod.
1
2
3
4
5
6
930357219
930359913
930357227
930357231
93035C060
930350000
Descr.
INTERRUTTORE 2P 16A
SCATOLA COMPLETA
LAMPADA 24V
PORTALAMPADA SPIA ROSSA
GR. CAVI TCM
TCM35 COMPLETO
Descr.
INTERRUPTER 2P 16A
CASE, COMPL.
WARNING LIGHT 24V
WARNING LIGHT HOLDER
TCM CABLE KIT
COMPLETE TCM35
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