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USE AND MAINTENANCE MANUAL
TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH
"RENTAL"
GE 40 KR-5
• Gruppo Elettrogeno
• Stromerzeuger
• Generating Set
• Grupo Gerador
• Groupe Electrogene
• Генераторная Установка
• Grupos Electrógenos
• Stroomaggregaten
M A D E
I N
I T A L Y
language
Codice
Code
Code
Codigo
CN1R50G19003
Kodezahl
Código
Код
Code
Edizione
Edition
Édition
Edición
01.2022
Ausgabe
Edição
Издание
Editie
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Summary of Contents for Mosa RENTAL
- Page 1 USE AND MAINTENANCE MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH Codice “RENTAL” Code Code Codigo GE 40 KR-5 CN1R50G19003 Kodezahl Código Код Code Edizione Edition Édition • Gruppo Elettrogeno • Stromerzeuger Edición 01.2022 • Generating Set • Grupo Gerador Ausgabe •...
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Page 3: Table Of Contents
INDEX 0. GENERAL INFORMATION M1.1 INTRODUCTION ........................PAG. 4 CE MARK ..........................PAG. 5 M1.4 SYMBOLS AND SAFETY PRECAUTIONS ................... PAG. 6 WARNINGS ..........................PAG. 7 M2.1 M2.5 SAFETY RULES ........................PAG. 8 1. GENERAL INFORMATION OF THE MACHINE DESCRIPTION OF THE MACHINE ....................PAG. 10 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: Ce Mark
CE MARKING GENERATING SETS 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: Safety Rules
SAFETY RULES GENERATING SETS - LIGHTING TOWERS 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 GENERATING SETS - LIGHTING TOWERS 2.5.1 SAFETY PRECAUTIONS DURING MAINTENANCE ADDITIONAL PRECAUTIONS FOR LIGHTING TOWERS • Make use of qualified personnel to carry out maintenance and troubleshooting. ATTENTION • It is mandatory to stop the engine before performing any maintenance on the machine.
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Page 10: Description Of The Machine
The RENTAL models are a super silenced generating sets. The machine construction incorporates an integral roll bar, one central lifting point, forklift pockets and rear canopy section that is hinged to provide full access to the engine for maintenance. -
Page 11: 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 12: 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 13: Transport And Handling
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 14 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.
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Page 15: Installation
INSTALLAZIONE - INSTALLATION - INSTALLATION INSTALACIÓN - LUFTZIRKULATION - INSTALAÇÃO УСТАНОВКА - INSTALLATIE... -
Page 16: M2.6 Installation And Advice
INSTALLATION INSTRUCTIONS ENVIRONMENTAL CONDITIONS GENERAL INSTALLATION CRITERIA Installation of a genset has to be planned by qualified and trained technicians, it has to be carried out by a competent ATTENTION organization with qualified personnel and proper equipment. ATTENTION Open gensets (SKID) have to be located in an area protec- ted from rain, snow, high humidity and direct exposure to the sun. - Page 17 In order to avoid potentially dangerous situations, area surrounding genset should be isolated so that unauthorized people will not be able to get close to the unit. Even if MOSA Engine and alternator when in operation produce heat: gensets are manufactured according to electromagnetic •...
- Page 18 INSTALLATION INSTRUCTIONS 2.6.2 Sample of outdoor installation with shelter Floor should be levelled and suitable to sustain genset weight. Thresholds on doors and openings should have a barrier in or- der to avoid liquids leaking. In case it is not possible to provide a door with a barrier, the genset should have a collection base appropriate for the quantity of liquid it contains, in any case dimensions of collection base must be in accordance to the...
- Page 19 INSTALLATION INSTRUCTIONS 2.6.3 For open gensets installed indoors, we recommend: Electro ventilator capacity can be calculated as follows: • The dimensions of the air outlets be such that they have at least the same area of the radiator; Transmitted heat [Kcal/h] •...
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Page 20: Set-Up For Operation Diesel Engine
SET-UP FOR OPERATION (DIESEL ENGINE) WATER COOLED SYSTEMS ATTENTION BATTERY The starter battery is supplied already Prolonged skin contact with the exhausted engine oil can charged and ready for use. cause cancer of the skin. Before starting the gen-set connect the If contact with oil cannot be avoided, thoroughly wash your cable + (positive) to the pole + of the bat- hands with soap and water as soon as possible. - Page 21 SET-UP FOR OPERATION (DIESEL ENGINE) 20.1 WATER COOLED SYSTEMS COOLING LIQUID AIR FILTER A mixture of 50% demineralized water and 50% low silicate Check that the dry air filter is correctly installed and that there ethylene glycol based coolant liquid must be used. are no leaks around the filter which could lead to infiltrations of Use a coolant free of: silicates, phosphates, borates, nitrites non-filtered air to the inside of the motor.
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Page 22: Earthing
EARTHING KIT EARTHING KIT WITHOUT GROUND FAULT INTERRUPTER EARTHING KIT WITH ISOMETER Machines equipped with insulation resistance monitor allow The protection against electric shock from contact indirect is intentionally not to connect the ground terminal PE (12) to an ensured by the “electrical separation” with equipotential bonding earthing system. - Page 23 START AND STOP Check daily NOTE Do not alter the primary conditions of regulation and do not touch the sealed parts. The engine is started and stopped by acting directly on the IL-4 AMF 9 controller Consult the controller manual for a complete knowledge of its characte- ristics and performance.
- Page 24 COMANDI - CONTROLS - COMMANDES - MANDOS - BEDIENELEMENTE - COMANDOS СИСТЕМЫ УПРАВЛЕНИЯ - BEDIENING T5-A3...
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Page 25: Starting And Stopping
CONTROLS DESCRIPTION Pos. Description Function Generator control unit IL4- Control board of the genset. AMF9 Starting and stopping the generator. Generator alarm management. Display of: alarms, measurements, operational messages. Controller power switch Controller power on/off switch. Forced Regeneration Button Starts the PDF forced regeneration process Inhibition Regeneration It inhibits the PDF forced regeneration process Button... -
Page 26: Ats - After Treatment System
ATS - AFTER TREATMENT SYSTEM KOHLER Generating sets with engines complying with the STAGE V (5) exhaust gas standard require special devices to reduce emissions of pollutants in the exhaust gas. Depending on engine power, the aftertreatment system includes the following devices: •... - Page 27 ATS - AFTER TREATMENT SYSTEM KOHLER DPF REGENERATION STRATEGIES REGENERATION SOOT LEVEL REGENERATION PROCESSES PASSIVE REGENERATION A natural and continous cleaning process. It occurs during normal engine operating conditions. Passive regene- ration does not impact machine operation or require operator involve- ment (250-500 °C) PASSIVE ASSISTED REGENERATION Passive regeneration can be induced by intervening on air intake...
- Page 28 ATS - AFTER TREATMENT SYSTEM KOHLER FORCED REGENERATION ACTIVATION PROCEDURE Warnings: 1. Ensure that the genset is in a well-ventilated outdoor • The regeneration inhibit command is ignored by the system location. if there is a request for manual regeneration (forced or If the fuel level indicator shows service) a low level, refuel the genset so that the •...
- Page 29 ATS - AFTER TREATMENT SYSTEM KOHLER DISPLAYING THE AFTER-TREATMENT STATUS The gen- set's controller provides information on the after- treatment system installed on the generator engine by the functions: • display of universal lamps (icons) • display of analogue and binary values • control of the aftertreatment regeneration function by command transmission to the ECU After-treatment screen The after-treatment screen is displayed automatically once one...
- Page 30 ATS - AFTER TREATMENT SYSTEM KOHLER LAMP NAME ACTIVE ICON INACTIVE ICON ALARM OUTPUT (LBO) Yellow warning lamp AHI ECU Yellow lamp ECU YELLOW LAMP This alarm is activated when ECU send information that ECU Yellow lamp is activated. LBO ALARM is not activated, after deactivation of lamp, alarm automatically disappears. This output is active when the ECU sends an active “yellow lamp” flag, i.e. it has detected a non-critical malfunction. This flag is taken from the DM1 frame on standard J1939 ECUs. Some ECUs provide this flag in their own proprietary fra- mes and some do not provide the flag at all. Red stop lamp AHI ECU Red lamp ECU RED LAMP This alarm is activated when ECU send information that ECU Red lamp is activated. LBO ALARM is not activated, after deactivation of lamp, alarm automatically disappears. This output is active when the ECU sends an active “red lamp” flag, i.e. it has detected a critical malfunction and the engine should not be operated until a service check is performed. This flag is taken from the DM1 frame on standard J1939 ECUs.
- Page 31 USING THE GENERATOR OPERATING CONDITIONS WARNING POWER It is absolutely forbidden to connect the unit to the public The electrical power expressed in kVA on an electricity- mains and/or another electrical power source . generating group is the available output power to the reference environmental conditions and nominal values for: voltage, frequency, power factors (cos ϕ).
- Page 32 USING THE GENERATOR 37.1 The frequency, and therefore the number of motor revolutions, SINGLE-PHASE LOADS is maintained constant by the motor’s speed regulation system. Power to monophase utilities by means of three-phase Generally, this regulator is of a mechanical type and presents generators requires some operating limitations.
- Page 33 USING THE GENERATOR 37.2 DIFFERENTIAL SWITCH USAGE WITH EAS AUTOMATIC START-UP PANEL The differential switch or differential relay guarantee protection The electricity-generating group in combination with the EAS against indirect contacts due to malfunction currents towards the automatic start-up panel forms a unit for distributing electrical ground.
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Page 34: Protection - Earth Leakage Relay
BEWARE: this operation is allowed only under the responsibility of personnel able to activate different solutions to ensure electri- cal protection of the system powered by the gen-set. USE OF THE DER3 / 0D MODEL (MOSA SET UP) Manual reset Regulation of intervention time: INST (instantaneous) Regulation of fault current: 30 mA Output relay: N.De... -
Page 35: M39.10 Protection - Isometer
ENGINE PROTECTION INSULATION MONITORING 39.10 LEGEND: NOTE Adjustment of Alarm threshold Set-alarm dip-switches DO NOT INTERVENE ON THE SETTING OF THE PROTEC- Led, pre-allarm indication TION SWITCH. BEFORE USING THE MACHINE CHECK Led , power indication Led Alarm indication THE ON WARNING LAMP LIGHTING. Test push-button Reset push-button Adjustment of- PRE-ALARM threshold... -
Page 36: 3-Way Valve Fuel System Kit
3-WAY VALVE FUEL SYSTEM KIT 29.2 This system allows to feed the motor of the generator both from its own tank and from an external tank of greater capacity. It consists mainly of two parts: - a three-way valve for the selection of the tank; - two hydraulic type quick disconnect couplings for the connec- tion of the hoses from the external tank. -
Page 37: M38.6 Tcm35 Remote Control
REMOTE CONTROL TCM 35 38.6 MAKE SURE The selector LOCAL START/REMOTE START (I6) of the generating set must be switched on LOCALSTART (with EP6). 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. -
Page 38: M40.2
TROUBLESHOOTING Problem Possible cause Solution ENGINE ECU RED light on (STAGE 5 1) The engine ECU has detected a severe malfunction 1) Turn off the engine immediately. engines only) operation. Ask for intervention of Service Department. ECU YLLOW light on (STAGE 5 1) The engine ECU has detected a malfunction. -
Page 39: Panel Mains/Genset
PANEL MAINS/GENSET PAC-I PAC-I The generating set in combination with the automatic switching panel MAINS/ GENSET PAC-I is a unit for distributing electrical energy within a few seconds in case of a power failure from the commercial electrical power line. Connect the PAC-I switching panel to connector X1 (the same connector dedicated to the connection of the TCM35 remote control) and put the control unit in AUTO MODE. -
Page 40: Maintenance
MAINTENANCE ATTENTION • 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 41 MAINTENANCE KDI STAGE V IMPORTANT ATTENTION The information given in the table is only indicative. Specific For the canopied machines there are routine instructions are given in the operation manuals. maintenance operations that require that the The engine and alternator manufacturers indicate specific operator climbs on top of the machine at a maintenance and control intervals: it is obligatory to consult height higher than 2 m.
- Page 42 MAINTENANCE 43.2 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.
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Page 43: Storage And Cast Off
STORAGE AND CUST OFF CUST OFF STORAGE + 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 44: M1.5
TECHNICAL DATA GENERATOR *Stand-by three-phase power 38 kVA (30.4 kW) / 400V / 54.8A **PRP three-phase power 34 kVA (27.2 kW) / 400V / 49A Frequency 50 Hz Cos ϕ ALTERNATOR self-excited, self-regulated, brushless Type synchronous, three-phase Insulation class ENGINE Make / Model KOHLER KDI 1903TCR Type / Cooling system... - Page 45 DIMENSIONI - DIMENSIONS - DIMENSIONS - DIMENSIONES ABMESSUNGEN - DIMENSÕES - РАЗМЕРЫ - AFMETINGEN 2.7.1 2100 2050 2150...
- Page 46 NOTE...
- Page 47 NOTE...
- Page 48 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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