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Mosa RENTAL GE 50 KR-5 Use And Maintenance Manual

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CN2L70G19003_EN
06-2022
Use and Maintenance Manual
D5260010
Generating set
RENTAL
GE 50 KR-5
Original instructions

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Summary of Contents for Mosa RENTAL GE 50 KR-5

  • Page 1 CN2L70G19003_EN 06-2022 Use and Maintenance Manual D5260010 Generating set RENTAL GE 50 KR-5 Original instructions...

  • Page 3: Table Of Contents

    Contents Contents Introduction ............................1 Foreword ............................1 Supplied documentation ........................2 Customer service ..........................2 Spare parts ............................2 Declaration of conformity ........................2 Unauthorized changes ........................2 Allowed and non-allowed use ......................2 1.8 Identification data ..........................3 Sound power level ..........................4 Safety ..............................5 Safety information ..........................5 Positioning of safety decal and information ..................6 2.2.1 Decal explanation ........................7 General precautions ...........................9...
  • Page 4 Contents 4.2.1 Main machine switch ......................26 4.2.2 Hearth leakage relay (model Type A - EU version) .............. 26 4.2.3 Residual current circuit breaker with overcurrent protection (RCBO) ........27 4.2.4 Residual current circuit breaker (present only for DGUV version) ........27 4.2.5 Isolation monitor (model Type B - version DGUV) ...............

  • Page 5: Introduction

    If the manual is lost, damaged or becomes illegible, request a copy to MOSA, indicating the model of the generating set, the serial number and the year of construction.

  • Page 6: Supplied Documentation

    (e.g. engine). Customer service The Technical Assistance and Spare Parts Service are available to the Customers. MOSA recommends that you contact the nearest authorised service centre for specialised intervention for all control and overhaul operations. In order to obtain quick and effective responses, indicate the Model and Serial Number shown on the identifi- cation plate (see “1.8 Identification data”).

  • Page 7: Identification Data

    1. Introduction Identification data The data identifying the generating set are given on the EC plate applied in the area indicated in the figure. They are necessary for spare parts requests and communications with the Customer Service Department. D5260020 Manufacturer 's data Machine data • Made in EU-ITALY: Year of manufacture • TYPE: model • SERIAL NO.: Serial number Machine technical data • KVA: Power (kVA/kW) • V: Rated voltage • A: Rated current •...

  • Page 8: Sound Power Level

    1. Introduction Sound power level The sound power level of the generating set is given on the decal applied in the area indicated in the figure. D5260030 The value indicates the guaranteed sound power level in compliance with Directive 2000/14/EC. Sound power level (LWA) - Unit of measurement dB(A): represents the amount of acoustic energy emit- • ted in the unit of time regardless of the distance of the measuring point.

  • Page 9: Safety

    2. Safety Safety Safety information Always respect the warnings contained in this manual and present on the decal applied to the machine. This allows the machine to be used safely, avoiding damage to property and injury or death to people. The following words and symbols were used to identify important safety messages.

  • Page 10: Positioning Of Safety Decal And Information

    2. Safety Positioning of safety decal and information D5260040...

  • Page 11: Decal Explanation

    2. Safety 2.2.1 Decal explanation • Pos. 1 Consult the manual Read the contents of the manual carefully before using the machine or carrying out maintenance operations on it. M734500253 Pos. 2 - Electrical voltage hazard • Stop the generating set before carrying out checks or maintenance.
  • Page 12 2. Safety Pos. 6 - Stop the engine before servicing • To avoid burns due to contact with hot parts, before carrying out checks or servicing of the machine, stop the engine and wait until they have cooled sufficiently. To avoid serious injury, do not insert limbs near the rotating parts without stopping the engine.

  • Page 13: General Precautions

    2. Safety General precautions Any errors during use, checks or maintenance could cause the risk of injury, even serious • Before performing the operations, read this manual and the decals applied to the machine and follow the warn- ings. If you don't understand any part of the manual, ask your Safety Officer for explanations.

  • Page 14: Fire Prevention

    2. Safety Fire prevention 2.4.1 Fire due to fuel, oil, coolant Avoid approaching any flame to flammable substances • such as fuel, oil, coolant. Do not smoke or use open flames near flammable sub- • stances. • Stop the generating set before refuelling. Make sure not to spill flammable substances on over- • heated surfaces or on parts of the electrical system. After refuelling, remove any spills and tighten all filling •...

  • Page 15: Handling Precautions

    2. Safety Handling precautions 2.5.1 Lifting by chains or ropes • Make sure that the handling area is clear of obstacles and people. • Lift the generating set using only the lifting points provid- ed and indicated by the decals. •...

  • Page 16: Transport With Towing Carriages

    2. Safety Widen the forks as much as possible to distribute the • weight evenly while keeping the generating set horizon- tal. D5260120 2.5.3 Transport with towing carriages • Do not tow the machine manually or with tow vehicles without the intended towing carriage. • Check the correct assembly of the machine to the drive device. •...

  • Page 17: Installation Precautions

    2. Safety Installation precautions 2.6.1 Installation site precautions Do not install machines or equipment near heat sources, in areas at risk with explosion hazard or fire • hazard. Install the machine at a safe distance from fuel tanks, from flammable material (rags, paper, etc.), from chemicals. Follow the instructions of the competent authorities. • To limit potentially dangerous situations, isolate the area around the generating set, thus preventing any unauthorized personnel from getting close to it. •...

  • Page 18: Precautions During Operation

    2. Safety Precautions during operation • Keep the doors closed during normal operation. • Access to the internal parts of the generating set must only be carried out for maintenance purposes. • Keep the area near the exhaust silencer free from objects such as rags, paper, cartons. The high temperature of the silencer could cause the objects to burn and cause a fire.

  • Page 19: Maintenance Precautions

    2. Safety Maintenance precautions Maintenance must be performed by qualified personnel. • • During maintenance, if unauthorized persons start the machine, there is a danger of serious personal injury or death. Do not allow unauthorized persons to approach the machine. Stop the machine and turn the battery disconnect switch to off. • • To avoid injury, do not perform maintenance with the engine running, if it is not necessary.

  • Page 20: Precautions For Disposal Of Waste Material

    2. Safety • Do not operate the battery without using protective gloves. The battery liquid contains corrosive sulphuric acid. D5260180 Do not smoke, avoid open flames and sparks near the • battery; exhaled vapours may cause the battery to ex- plode. D5260170 2.10 Precautions for disposal of waste material • Be sure to store the waste liquid in containers or tanks. •...

  • Page 21: Technical Data

    3. Technical data Technical data Machine dimensions 2350 mm 2300 mm 2401 mm 1050 mm 1100 mm D5260240...

  • Page 22: Technical Data

    3. Technical data Technical data Rated power 50 kVA (40 kW) / 400V / 72.2A Three-phase stand-by power ( 45 kVA (36 kW) / 400V / 65A Three-phase PRP power ( Frequency 50 Hz Cosφ General specifications 245 ℓ Fuel tank capacity Autonomy (75% PRP) 29 h Protection IP 44 Maximum dimension on base 2401x1100x1575 Weight (Dry) 1270 kg Measured sound power L...

  • Page 23: Description

    4. Description Description The Generating Set is a machine that transforms mechanical energy, generated by a combustion engine, into electrical energy through an alternator. Main components 4.1.1 External components D5260230...
  • Page 24 4. Description Control panel Control panel access door Electrical distribution panel with three-phase and single-phase output sockets Emergency button Fuel tank cap Closing plate Oil drain plug Coolant drain plug Engine compartment access door 10 - Fluid drain plug 11 - Fuel drain plug 12 - Radiator compartment access door...

  • Page 25: Internal Components

    4. Description 4.1.2 Internal components D5260690 Coolant level sensor Radiator cap Engine 4 - Engine air filter Fuel supply pump Fuel tank Battery Battery disconnect switch 9 - Oil filler plug 10 - Fuel prefilter 11 - Fuel tank cleaning access 12 - Alternator...
  • Page 26 4. Description D5260700 12 - Liquid leak sensor in base 13 - Fuel filter 14 - Oil level dipstick 15 - Oil filter 16 - Dummy load 17 - Engine control module 18 - Ambient temperature sensor 19 - Exhaust post-treatment unit (ATS)

  • Page 27: Control Panel And Electrical Panel Components

    4. Description 4.1.3 Control panel and electrical panel components Type A - EU version D5260330 Control panel power switch (ON-OFF) DPF (Diesel Particulate Filter) manual regeneration button DPF (Diesel Particulate Filter) regeneration inhibition button Command and control unit Protection fuses Buzzer 7 - Ground differential relay...
  • Page 28 4. Description Type B - DGUV version D5260340 Control panel power switch (ON-OFF) DPF (Diesel Particulate Filter) manual regeneration button DPF (Diesel Particulate Filter) regeneration inhibition button Command and control unit Protection fuses Buzzer Insulation monitor Main machine switch Residual current circuit breaker (RCCB) (4P 300mA Type B) for three-phase 63A 400V sockets 10 - Residual current circuit breaker with overcurrent protection (RCBO) (4P 32A - 30mA Type B) for three- phase 32A 400V sockets...
  • Page 29 4. Description D5260710 Engine circuit protection fuses Service switch Dummy load switch Ground cable collector Power terminal block 6 - Auxiliary terminal block for the following connections: - Global alarm - Remote start and stop - Connection to PAC-I switchboard...

  • Page 30: Electrical Protection

    4. Description Electrical protection 4.2.1 Main machine switch The generating set is protected against short circuits and overloads by a circuit breaker (1) located upstream of the system. Overload protection tripping is not instantaneous; it follows an overcurrent/time characteristic. The greater the overcur- rent, the shorter the tripping time. The rated tripping current refers to an operating temperature of 30°C.

  • Page 31: Residual Current Circuit Breaker With Overcurrent Protection (Rcbo)

    4. Description The differential relay has 2 tests, 1 of which is carried out automatically by the instrument: • Manual test (test button). • Automatic test of toroid-relay connection and release reel relay. The differential relay can operate correctly even in the presence of harmonic distortion or with very disturbed signals. If the internal temperature exceeds the operating threshold, the Fault led (3) flashes. The interruption of operation due to a failure of the torus (breakage of the connecting wire) or a fault of part of the internal circuits, leads to the automatic intervention of the protection.
  • Page 32 4. Description SRI3/ D2 operation • ON indicator (4) indicates that the equipment is powered. • Pressing the test button (6) for at least 5 seconds, turns on the Alarm (5) and Pre-alarm (3) LEDs. When the button (6) is released, the Pre-alarm led (3) turns off and the Alarm led (5) remains ON. Press • the test button (6) again to turn off the Alarm led (5). • If the isolation resistance drops below the set pre-alarm value, the Pre-alarm led (3) lights up and the contact of the Pre-alarm relay switches.

  • Page 33: Optional Fittings

    4. Description Optional fittings 4.3.1 3-way kit for fuel supply The 3-way kit allows you to supply the engine of the generating set from the fuel tank of the machine or from an external tank of greater capacity to increase the operating range. D5260410 It consists mainly of two parts: •...

  • Page 34: Pac-I Mains/Generator Switchboard

    4. Description 4.3.2 PAC-I mains/generator switchboard PAC-I D5260420 The generating set combined with a PAC-I mains/generator switchboard, forms a complex for the supply of electricity within a few seconds from the sudden absence of the commercial electricity grid. Connect the PAC-I switchboard to the auxiliary terminal block as indicated on the generating set wiring dia- gram and bring the control unit and control it in AUT (automatic) mode.

  • Page 35: Installation

    5. Installation Installation WARNING Before proceeding with the installation, carefully read section Safety - “2.6 Installation precau- • tions” and “2.7 Precautions during operation”. The installation and the electrical connection described in this chapter are indicative. • For these operations, it is necessary to contact Specialized Technicians who must issue the necessary certifications.

  • Page 36: Indoor Installation

    5. Installation Indoor installation Important • The room where the generating set will be installed must comply with the legislation in force at the place of installation. Installation of the generating set indoor must be carried out in accordance with the instructions described. D5260270 Fig.

  • Page 37: Supporting Floor

    5. Installation 5.3.1 Supporting floor For a correct support of the electronic unit and to avoid the transmission of vibrations, it is necessary to build a reinforced concrete platform (7) on the floor, isolated from the rest of the structure. The generating set frame must be fixed to the platform (7) with dowels or anchor bolts. The platform must have a length (D) and a width (E) greater than 400 mm (200 mm per side) with respect to the support base of the generating set (200 mm per side).

  • Page 38: Grounding With Isolation Monitor

    5. Installation 5.4.4 Grounding with isolation monitor In machines equipped with an insulation monitor, connection of the grounding terminal (1) to a grounding system is not required. Located on the front of the machine, the isolation monitor continuously monitors the ground insulation of the active parts.

  • Page 39: Operation

    6. Operation Operation WARNING Before starting the machine, carefully read section “2. Safety”. • It is forbidden to connect the set to the public grid and/or other source of electricity. • Operating conditions 6.1.1 Power The electrical power of the generating set, expressed in kVA, is the available output power at the reference environmental conditions and at the rated values of: voltage, frequency, power factor (cos ϕ).
  • Page 40 6. Operation For cos ϕ values lower than 0.8, the alternator must be downgraded, because, at the same apparent power, the alternator should provide a greater reactive power. For the reduction coefficients, contact the Technical Support Service. Asynchronous motor start Starting an asynchronous motor by a generating set can be critical, due to the high starting currents that the asynchronous motor requires (Iavv. = up to 8 times rated current In.). The starting current must not exceed the overload current allowed by the alternator for short periods, gener- ally 250-300% for 10-15 seconds.

  • Page 41: Checks Before Start-Up

    6. Operation Checks before start-up 1 - Check that the battery disconnect switch is turned ON. D5260720 2 - Check the oil, fuel and coolant levels. 3 - Check that the engine compartment, radiator and battery access doors are locked. 4 - Check that there are no oil, fuel and coolant leaks.
  • Page 42 6. Operation 3 - Turn the control panel power switch (2) ON. D5260440 4 - Press the start button (3) to launch the generating set start sequence. Note: The start button only works in MAN mode. 5 - Before supplying a load, let the engine run for the time shown in the following table.

  • Page 43: Stopping The Generating Set

    6. Operation Stopping the generating set 1 - Turn off the loads connected to the generating set. 2 - Set the main machine switch (2) to OFF (insertion lever downwards). D5260430 3 - Press the stop button (5) to launch the generating set stop sequence. The engine stops at the end of the cooling cycle. For immediate stop, press the stop button (5) again.

  • Page 44: Exhaust Post-Treatment

    6. Operation Exhaust post-treatment Generating sets with engines complying with STAGE V exhaust gas regulations require special devices to reduce the emissions of pollutants in exhaust gases. Depending on the engine output, the after-treatment system includes the following devices: Doc (Diesel Oxidation Catalyst): catalyst to purify exhaust gases • DPF (Diesel Particulate Filter): particulate filter that captures soot in exhaust gases • SCR (Selective Catalytic Reduction): device that purifies nitrogen oxides (NOx) in engine exhaust gases. • On engines with power from 19 kW to 56 kW, there are DOC and DPF devices. On engines with a power greater than 56 kW, there are Doc, DPF and SCR devices. 6.6.1 Particle filter (DPF) regeneration Regeneration is the term used to describe DPF cleaning.

  • Page 45: Dpf Regeneration Strategies

    6. Operation 6.6.2 DPF regeneration strategies Particle per- Level Regeneration processes centage Passive regeneration • It is a natural and continuous cleaning process. Occurs during normal engine operating condition. 0% - 30% Passive regeneration does not affect the operation of the machine and does not require the involvement of the operator (250-500 °C). Passive assisted regeneration •...

  • Page 46: Forced Regeneration Activation (Manual)

    6. Operation Automatic regeneration Automatic DPF regeneration does not require any interven- tion by the operator. In case of active regeneration, the indicator light on the con- trol and command panel that indicates the high temperature of the exhaust system switches on. D5260490 Manual regeneration When the DPF clogging level reaches 90% or higher (levels...
  • Page 47 6. Operation 1 - Check the fuel level and refuel if necessary to allow a complete regeneration process. 2 - Disconnect all connected loads and leave the main ma- chine switch on (insertion lever upwards). 3 - Press and hold the manual regeneration button for at least 3 sec.
  • Page 48 6. Operation Dummy load The generating set is equipped with a resistive bench positioned in front of the radiator that allows the system to correctly carry out all the regeneration processes, regardless of the electrical utilities connected to the generating set. Activation of the dummy load is automatically controlled by the generator control unit, which continuously compares the regeneration signal coming from the engine with the electri-...

  • Page 49: After-Treatment Status Display

    6. Operation After-treatment status display The generator control panel provides information on the after-treatment system installed on the generator engine through the following functions: • Universal lamps display (icons). • Display of analogue and binary values. • Control of the post-treatment regeneration function by transmitting commands to the control unit. After-treatment screen The after-treatment screen is automatically displayed once one of the warning lights activates or changes state.
  • Page 50 6. Operation Active indi- Inactive indi- Exit activated Indicator light Alarm name cator light cator light This alarm is activated when the control unit sends information that the red light of the control unit is acti- vated. The ALARM output is not activated, after the light is turned off, the alarm disappears automatically. This output is active when the control unit sends an active "red light" flag, that is, it has detected a critical malfunction. Do not run the engine until a service check is carried out. This flag is taken from DM1 on J1939 standard ECUs. Some controllers provide this flag in their own pro- prietary frames, others do not provide the flag.

  • Page 51: Maintenance

    7. Maintenance Maintenance WARNING Before proceeding with maintenance, carefully read section “2. Safety”. • Refuelling Use fuel, coolant and lubricants according to the ambient temperature. 7.1.1 Fuel The fuel required for stage V engines must comply with EN590 and ASTM D975. The cetane number of the fuel should be at least 45.

  • Page 52: Engine Oil

    7. Maintenance 7.1.2 Engine oil To ensure adequate protection of the engine and keep it efficient for a long time, use only the recom- • mended oil. Using different oils can reduce the life of the engine. • The viscosity must be appropriate to the ambient temperature. The oil to be used must comply with the following specifications: • CJ-4 Low S.A.P.S ACEA E6 Low S.A.P.S. Low S.A.P.S. (low sulphated ash, phosphorus, sulphur oil) keeps the catalyst in good working condition. SAE oil classification In the SAE classification, oils are identified according to the viscosity.

  • Page 53: Coolant

    7. Maintenance 7.1.3 Coolant The engine cooling system is fuelled with OAT: ENI ANTIFREEZE SPEZIAL coolant, mixed at 50% with dem- ineralised water. It is recommended to continue using the same coolant. If the type of coolant is changed for refuelling, the system must be thoroughly washed. By mixing with each other, the residues of additives of different types contained in the different liquids would create gelatinous substances that could obstruct the system. Use a mixture of 50% demineralised water and 50% low silicate ethylene glycol coolant.

  • Page 54: Checking And Cleaning The Engine Air Filter

    7. Maintenance 2 - Remove the cap (2) and pour the coolant into the radia- tor. 3 - Top up the liquid until it covers the pipes inside the radia- tor by about 5 mm. Note: Do not overfill the radiator; allow room for coolant expan- • sion. 4 - Refit the cap (2) and tighten securely. D5260770 5 - After the top-up operations, run the engine for a short period, check the coolant level again and refill if neces-...

  • Page 55: Routine Maintenance

    7. Maintenance Routine maintenance WARNING Pay the utmost attention to the generating sets equipped with an automatic or remote interven- • tion system. Make sure that the generating set does not start during routine maintenance or repair opera- tions by carrying out the following operations: ◦...

  • Page 56: Maintenance Of Generating Sets With Automatic Intervention System

    7. Maintenance Every 5000 hours • Check battery charging alternator • Check starter • Replace ATS • Replace coolant Every 8000/10000 hours • Partial engine overhaul • Replace alternator bearings • Replace noise absorbing material Every 16000/20000 hours • Complete engine overhaul Maintenance of generating sets with automatic intervention sys- For generating sets preset for automatic intervention, in addition to carrying out all the periodic maintenance operations required for normal use, some operations necessary for the particular type of use must be carried...

  • Page 57: Disposal

    7. Maintenance Disposal WARNING Before refuelling, read “2.10 Precautions for disposal of waste material” and “2.11 Disposing of • the generating set”. In the event of disposal of the equipment or parts of it (oils, hoses, plastic materials, etc.), comply with the regulations in force in the country in which this operation is carried out.
  • Page 58 7. Maintenance NOTES:...

  • Page 59: Alarms

    8. Alarms Alarms This chapter lists the alarms transmitted by the engine control unit. DTC code Description of the malfunction code SPN code FMI code Camshaft phase sensor and crankshaft revolutions sensor: synchro- P0016 nization error P0069 Atmospheric pressure sensor cross-check P0070 Ambient temperature physical limit check diagnosis, max. P0071 Ambient temperature physical limit check diagnosis, min.
  • Page 60 8. Alarms DTC code Description of the malfunction code SPN code FMI code P0182 Fuel temperature sensor signal too low. P0183 Fuel temperature sensor signal too high. FTB 2A - Fuel pressure sensor signal (maintains intermediate val- P0191 ue). P0191 FTB 25 - Fuel pressure sensor signal (signal too high or too low) P0191 FTB 24 - Fuel pressure sensor signal (incorrect reference value)
  • Page 61 8. Alarms DTC code Description of the malfunction code SPN code FMI code Turboboost time-out. Injector 4 (4 cyl engine)/ Injector 2 (3 cyl en- P02F1 1395 gine) (No peak injection current) P0336 Crankshaft position sensor - Malfunction. P0337 Crankshaft position sensor - No pulses. P0341 Camshaft position sensor - Malfunction.
  • Page 62 8. Alarms DTC code Description of the malfunction code SPN code FMI code CPU failure; main CPU failure P0606 2802 CPU failure; main CPU failure P0607 2802 P060C MSC communication error 536092 P060D SPI communication error (Ocean) 536093 P060E Atmospheric pressure sensor ECU internal communication error 536094 Condenser charge circuit injector fault (insufficient charge) P0611 P0615 Starter engine switch short circuit to battery...
  • Page 63 8. Alarms DTC code Description of the malfunction code SPN code FMI code P1219 Engine stall after PLV opening P1220 Common rail pressure does not reach target value P1221 Common rail pressure below target limit P1451 DPF (physical) removal monitor function 3936 P1562 Sensor exchange detection signal...
  • Page 64 8. Alarms DTC code Description of the malfunction code SPN code FMI code Injector control system output short circuit to ground, injectors 2 and P2150 523352 P2151 Injector control system output short circuit to battery, Injector 2 or 3. 523352 P2226 Ambient pressure physical limit check diagnosis, max.
  • Page 65 8. Alarms DTC code Description of the malfunction code SPN code FMI code U0408 TSC1RC Cycle counter test 3349 U0411 EGR valve transmission error and/or received signal error 2791 U1001 Node error on Can2 1084...
  • Page 66 8. Alarms NOTES:...
  • Page 68 MOSA div. della BCS S.p.A. Viale Europa, 59 20047 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...

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