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USE AND MAINTENANCE MANUAL
TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH
POWER WELDERS
TS 400 YS (STAGE V)
• Motosaldatrice
• Schweißaggregat
• Engine Driven Welder
• Motosoldadora
• Motosoudeuse
• По Вышкам
• Motosoldadoras
M A D E
I N
I T A L Y
language
Codice
Code
Code
C1BQ30699003
Codigo
Kodezahl
Código
Код
Edizione
Edition
Édition
Edición
10.2019
Ausgabe
Edição
Издание
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Summary of Contents for MOSA Weld TS 400 YS
- Page 1 USE AND MAINTENANCE MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH Codice POWER WELDERS Code Code C1BQ30699003 TS 400 YS (STAGE V) Codigo Kodezahl Código Код Edizione Edition Édition • Motosaldatrice • Schweißaggregat Edición 10.2019 • Engine Driven Welder •...
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Page 3: Table Of Contents
INDEX 0. GENERAL INFORMATION M1.1 INTRODUCTION ......................... PAG. 4 M1.4.2 CE MARK ........................... PAG. 5 SYMBOLS AND SAFETY PRECAUTIONS ................PAG. 6 WARNINGS ........................PAG. 7 M2.1 M2.5.1... SAFETY RULES ........................PAG. 8 1. GENERAL INFORMATION OF THE MACHINE DESCRIPTION OF THE MACHINE ..................PAG. 12 RECORDING DATA ...................... -
Page 4: Introduction
INTRODUCTION Dear Customer, The Manufacturer shall not be liable for ANY USE OF THE PRO- We wish to thank you for having bought a high quality set. DUCT OTHER THAN THAT PRECISELY SPECIFIED IN THIS Our sections for Technical Service and Spare Parts will work at MANUAL and is thus not liable for any risks which may occur as best to help you if it were necessary. -
Page 5: M1.4.2 Ce Mark
CE MARKING ENGINE DRIVEN WELDER 1.4.2 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. -
Page 6: Symbols And Safety Precautions
SYMBOLS AND SAFETY PRECAUTIONS SYMBOLS IN THIS MANUAL DANGER - The symbols used in this manual are designed to call your GENERAL ADVICE - If the advice is not respec- attention to important aspects of the operation of the machine ted damage can happen to persons or things. -
Page 7: Warnings
WARNINGS FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas or whate- ver event which may cause serious injuries or death, predispose the first aid in accordance with the ruling labour accident standards or of local instructions. -
Page 8: M2.5.1
SAFETY RULES ENGINE DRIVEN WELDERS GENERAL SAFETY INSTRUCTIONS • Do not replace the tires with types different from the original + NOTE: the information contained in this manual are ones. subject to change without notice. • Check that the brakes and the optical signaling of the trailer are working properly. - Page 9 SAFETY RULES ENGINE DRIVEN WELDERS 2.5.1 SAFETY PRECAUTIONS DURING INSTALLATION AND USE Do not instal equipments closed to heat source, to explosion or fire risk area. Always locate the machine on a flat and solid ground, so as to avoid tipping, slipping or falling during operation. Avoid using the machine on slopes greater than 10 degrees.
- Page 10 SAFETY RULES ENGINE DRIVEN WELDERS 2.5.2 SAFETY PRECAUTIONS DURING MAINTENANCE Make use of qualified personnel to carry out maintenance and troubleshooting It is mandatory to stop the engine before performing any main- tenance on the machine. Always use protective devices and suitable equipment. Do not touch the engine, the exhaust pipes and the muffler during operation or immediately after.
- Page 11 SAFETY RULES ENGINE DRIVEN WELDERS 2.5.3 ADDITIONAL REQUIREMENTS FOR ENGINE DRIVEN WELDERS Do not touch parts with OCV, it can cause mortal shock or heavy born. OCV is active at welding stick and auxiliary side when welding generating set is working. Do not manage electric devices and welding stick whit feet, hands or wet dresses.
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Page 12: Description Of The Machine
DESCRIPTION OF THE MACHINE The TS 400 YS is a unit which ensures the dual function as: a) a current source for are welding b) current generator for generating auxiliary Unit meant for industrial and professional use. Powered by an endothermic engine; it is composed of various parts such as: engine, alternator, electric and electronic controls, the fairing at a protective structure. -
Page 13: Recording Data
RECORDING DATA The manual is for the range of machines indicated on the front cover. With the scope to facilitate the search of the spare parts and maintain information of the bought machine, is necessary to record some data. Please write the requested data inside the squares to side: Model of machine Serial number of the machine Serial number of the engine... -
Page 14: Machine Unpacking
MACHINE UNPACKING 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. -
Page 15: M4.2
TRANSPORT AND HANDLING GENERAL PRECAUTIONS WHEN HANDLING THE MA- MOVING METHOD CHINE. The generating sets are lifted with different methods according to the unit’s configuration. Below are the main methods of mo- ving/lifting the genset. ATTENTION MOVING THE GENERATING SET VIA FORKLIFT When lifting with a forklift it is necessary to fork the baseframe sideways so that the forks stick out from one side to the other When moving/lifting a genset it is imperative to be ex-... - Page 16 TRANSPORT AND HANDLING 4.2.1 MOVING THE GENERATING SET VIA CABLES OR CHAINS MOVING BY SITE TROLLEY / TRAILER use should be respected. BEWARE DO NOT TOW the generating set without trailer, be it manually or using a vehicle. Trolleys/trailers should only be used to move the generating SITE TOW CTL: set for which they were designed.
- Page 17 INSTALLAZIONE - INSTALLATION - INSTALLATION - INSTALACIÓN - LUFTZIRKULATION INSTALAÇÃO - УСТАНОВКА - INSTALLATIE M1.4...
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Page 18: Installation
INSTALLATION AdvIceS eNGINe dRIveN WeLdeR INSTALLATION AND ADVICE BEFORE USE INSTALLATION Always instal the welder machine The operator of the welder is responsible for the security of the on a hard and plan surface in order people who work with the welder and for those in the vicinity. to avoid rollovers, slips or falls whi- le working;... -
Page 19: Electromagnetic Compatibility
ELECTROMAGNETIC COMPATIBILITY (EMC) ENGINE DRIVEN WELDERS This equipment is built in compliance with standard IEC- The size of the surrounding area to be considered will depend EN60974-10. on the structure of the building and other activities that are The equipment should be installed and used in accordance taking place. -
Page 20: Set-Up For Operation Diesel Engine
SET-UP FOR OPERATION (DIESEL ENGINE) WATER COOLED SYSTEMS BATTERY WITHOUT MAINTENANCE COOLING LIQUID The starter battery is supplied already charged and ready for use. ATTENTION Before starting the gen-set connect the cable + (positive) to the pole + of the bat- tery, by properly tightening the clamp. -
Page 21: Earthing
Earthing Earthing WithOUt grOUnD FaULt intErrUPtEr Earthing With isOmEtEr The protection against electric shock from contact indirect is Machines equipped with insulation resistance monitor allow intentionally not to connect the ground terminal PE (12) to an ensured by the “electrical separation” with equipotential bonding earthing system. -
Page 22: Starting And Stopping
STARTING AND STOPPING RGK420SA After the starting, keep the engine runs for a few minutes before Check daily the energy withdrawal. Check the tab: TEMPERATURE TIME ≤ - 20° C 5 min. da - 20° C a -10°C 2 min. NOTE da - 10°... - Page 23 COMANDI - CONTROLS - COMMANDES MANDOS - BEDIENELEMENTE - COMANDOS СИСТЕМЫ УПРАВЛЕНИЯ - BEDIENING D-Z2 Pos. Descrizione Description Description Referenzliste Presa di saldatura (only gouging) Welding socket (only gouging) Prise de soudage (only gouging) Schweißbuchse (only gouging) Presa di saldatura ( + ) Welding socket ( + ) Prise de soudage ( + ) Schweißbuchse ( + )
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Page 24: Controls
CONTROLS DESCRIPTION Pos. Description Function c.c. socket (Only Gouging) Outlet used only for cutting works c.c. welding sockets (+) Connection sockets for welding cables c.c. socket only gouging Outlet used only for cutting works Welding current regulator Allows the regulation of the welding current Welding arc potentiometer Turning clockwise the arc control is increased Remote control (connector) -
Page 25: M34
USE AS WELDER ADJUSTING THE WELDING CURRENT This symbol (Norm EN 60974-1 security standards for arc welders ) signifies that the welder can be used in areas with increased risk of electrical shock. The welding current is regulated by tur- ning knob “T”... - Page 26 USE AS WELDER 34.1 WELDING ARC CONTROL VRD SWITCH Set the welding arc using adjuster knob It is possible to exclude the VRD function by (P) so as to abtain, for the chosen current acting on the switch located inside the electric value, the best arc characteristic according box.
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Page 27: M37
UsE As gEnErAtor EngInE DrIVEn WELDErs VOLTAGE WARNING In some types of generators (asynchronous) the no-load vol- tage can be even higher than 10% with respect to its nominal value; for example, for nominal voltage, three-phase 400Vac It is absolutely forbidden to connect the unit to the public mains and/or another electrical power source . - Page 28 UsE As gEnErAtor EngInE DrIVEn WELDErs 37.1 ELECTRIC PROTECTIONS THERMIC PROTECTION Generally present to protect against overloads on an individual THERMAL-MAGNETIC SWITCH power socket c.a. When the nominal operating current has been exceeded, the + NOTE: for some types of alternators (asynchronous alter- protection device intervenes by cutting off power to the socket.
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Page 29: Recommended Welding Parameters
RECOMMENDED WELDING PARAMETERS WELDING WITH ELECTRODES - riempimento di saldatura - filling welding 10 mm 2 mm Vertical up - prima passata di saldatura - first coat welding e 6010 - ellulose first Coat welding Recommended electrode Welding thickness (mm) Diameter electrode (mm) Ampère Arc Control 1/9... -
Page 30: Recommended Electrodes
RECOMMENDED ELECTRODES (IN ACCORDANCE WITH A.W.S STANDARD) The information here below are to be intended only as indicative since the above norm is much larger. For further details please see the specific norms and/or the manufacturers of the product to be used in the welding process. RUTILE ELECTRODES: E 6013 Easily removable fluid slag, suitable foe welding in all position. -
Page 31: M40.1
TroubleshooTing 40.1 Problem Possible cause Solution ENGINE P1 - The motor does not 1) Emergency button (L5) pressed 1) Unblock start up 2) Preheating (where it is assembled) 2) Lacking or insufficient preheating phase for sparkplugs. Malfunction in circuit: repair 3) Engine control unit or starting key faulty 3) Replace 4) Battery low... - Page 32 TroubleshooTing 40.1.1 Problem Possible cause Solution WELDING P1 - No welding current but 1) Potentiometer defect in welding current 1) Replace potentiometer auxiliary output is OK control 2) Check that cables from current sensor to 2) Welding current signal interrupter card are in perfect state 3) Current sensor faulty 3) Replace current sensor...
- Page 33 TroubleshooTing 40.1.2 Problem Possible cause Solution GENERATION P1 - Absence of output 1) Main switch in OFF position 1) Check and switch ON voltage 2) Differential protection device tripped 2) Check on the entire installation: cables, (Differential switch, differential relay) connections, utilities connected have no de- fective sheathing which may cause incorrect currents to ground...
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Page 34: Maintenance
MAINTENANCE 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 at- tention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open. -
Page 35: Maintenance Scheduled Yanmar Tnv
MAINTENANCE SCHEDULED YANMAR TNV IMPORTANT The engine and alternator manufacturers indicate specific maintenance and control intervals: it is obligatory to consult the books, OPERATION AND MAINTENANCE of the engine and alternator provided with the generator you are using. If such documents are not supplied with the generator set, ask for a copy to the customer service. The information given in the table is only indicative. -
Page 36: Storage And Disassemble
STORAGE And diSASSEmblE STORAGE DISASSEMBLE + Have qualified personnel disassemble the machine and In case the machine should not be used for more than 30 days, dispose of the parts, including the oil, fuel, etc., in a correct make sure that the room in which it is stored presents a suitable manner when it is to be taken out of service. -
Page 37: Technical Data
TECHNICAL DATA GENERATOR TS 400 YS Three-phase generation 16 kVA / 400 V / 23.1 A Single-phase generation 10 kVA / 230 V / 43.5 A Single-phase generation 5 kVA / 110 V / 45.5 A Single-phase generation 5 kVA / 48 V / 104 A... -
Page 38: M1.6
TECHNICAL DATA D.C. WELDING (CONSTANT CURRENT) TS 400 YS Welding processes SMAW (STIK - Shielded Metal Arc) GTAW (TIG Contact starting) Welding current 20A ÷ 400A Welding current electronic regulation continues on 2 scales: 20A ÷ 200A / 20A ÷ 400A... -
Page 39: M2.7.1 Dimensions
DIMENSIONI - DIMENSIONS - DIMENSIONS - DIMENSIONES - ABMESSUNGEN DIMENSÕES - РАЗМЕРЫ - AFMETINGEN 2.7.1 1720 1300 57.5 1680 1653 2598... - Page 40 NOTE...
- Page 41 NOTE...
- Page 42 NOTE...
- Page 44 MOSA div. della BCS S.p.A. Viale Europa, 59 20090 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...
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