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Mosa GE 85 PSX Use And Maintenance Manual

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USE AND MAINTENANCE MANUAL
GE 85 PSX
GE 115 PSX
• Gruppi Elettrogeni
• Generating Sets
• Groupe Electrogene
• Grupos electrógenos
• Stromerzeuger
M A D E
I N
I T A L Y
Codice
Code
841169003
Codigo
Kodezahl
Edizione
Edition
02.2015
Edición
Ausgabe

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Summary of Contents for Mosa GE 85 PSX

  • Page 1 USE AND MAINTENANCE MANUAL GE 85 PSX Codice GE 115 PSX Code 841169003 Codigo Kodezahl • Gruppi Elettrogeni Edizione • Generating Sets Edition 02.2015 • Groupe Electrogene Edición • Grupos electrógenos Ausgabe • Stromerzeuger M A D E I T A L Y...
  • Page 3 DESCRIPTION OF THE MACHINE GE 85 - 115 PSX REV.2-02/15 The generating set GE is a unit which transforms the mechanical energy, generated by a combustion engine, into electric energy, through an alternator. The unit is composed by: a base, a tank, an engine/alternator unit fixed on the base by elastic dampers, a roll-bar, with hook for an easy and sure lifting, a base complete with doors for a quick access to the engine, to the air filter and to the battery.
  • Page 4 INDEX GE 85 - 115 PSX REV.1-02/15 DESCRIPTION OF THE MACHINE M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARKING M 1.5 TECHNICAL DATA M 2 ... WARNINGS M 2.1 SYMBOLS AND SAFETY PRECAUTIONS M 2.6 INSTALLATIONS AND ADVICE M 2.7 INSTALLATION M 2.7.1...
  • Page 5 (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 documen- tation are registered by the respective owners.

  • Page 6: Notes About The Manual

    Notes REV.1-03/14 INFORMATION INFORMATION OF GENERAL TYPE In the envelope given together with the machine and/or Dear Customer, set you will find: the manual for Use Maintenance and We wish to thank you for having bought a high quality set. Spare Parts, the manual for use of the engine and the tools (if included in the equipment), the guarantee (in the Our sections for Technical Service and Spare Parts will...
  • Page 7 CE MARKING REV.7-02/14 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.

  • Page 8: Technical Data

    TECHNICAL DATA GE 85 PSX REV.2-02/15 GENERATOR *Stand-by three-phase power 88 kVA (70.4 kW) / 400 V / 127 A *PRP three-phase power 80 kVA (64 kW) / 400 V / 115 A * PRP Single-phase power 29 kVA / 230 V / 126 A...
  • Page 9 TECHNICAL DATA GE 115 PSX REV.2-02/15 GENERATOR *Stand-by three-phase power 110 kVA (88 kW) / 400 V / 159 A *PRP three-phase power 100 kVA (80 kW) / 400 V / 144 A * PRP Single-phase power 36.5 kVA / 230 V / 159 A Frequency 50 Hz Cos ϕ...
  • Page 10 WARNINGS REV.1-02/14 The installation and general warnings regarding operations are aimed achieving correct use of the machine and/or apparatus in the place where it is used as a genset and/or motor welder. - Advice to the User about the safety: + NB: The information contained in the manual can be changed without notice.

  • Page 11: Symbols And Safety Precautions

    SYMBOLS AND SAFETY PRECAUTIONS REV.2-06/10 SYMBOLS PROHIBITIONS No harm for persons Use only with safety clothing - STOP - Read absolutely and be duly attentive It is compulsory to use the personal protection means given in equip- ment. Use only with safety clothing - Read and pay due attention It is compulsory to use the personal protection means given in equipment.

  • Page 12: Outdoor Installation

    Installation instructions REV.0-06/10 General installation criteria Outdoor installation Installation of a genset has to be planned by qualified and ATTENTION trained technicians, it has to be carried out by a competent organization with qualified personnel and proper equip- All generating sets are equipped with a control system ment.

  • Page 13: Temporary Outdoor Installation

    Even if MOSA gensets are ma- Engine and alternator when in operation produce heat: nufactured according to electromagnetic compatibility •...

  • Page 14: Indoor Installation

    Installation instructions 2.6.2 REV.0-06/10 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 order 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 H=ALTEZZA G.E.

  • Page 15: Exhaust Piping

    Installation instructions 2.6.3 REV.0-06/10 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] Fan Capacity [m /h]= •...

  • Page 16: Installazione Installation Installation

    INStALLAZIONE LuFtZIRkuLAtION INStALLAtION INStALACIóN GE 85 - 115 PSX INStALLAtION REV.1-04/08...
  • Page 17 DIMENSIONI ABMESSuNGEN DIMENSIONS DIMENSIONES GE 85 - 115 PSX 2.7.1 DIMENSIONS REV.0-11/06...
  • Page 18 DIMENSIONI ABMESSuNGEN DIMENSIONS DIMENSIONES GE 85 - 115 PSX 2.7.2 DIMENSIONS REV.0-06/08...
  • Page 19 DIMENSIONI ABMESSUNGEN DIMENSIONS DIMENSIONES GE 85 - 115 PSX 2.7.3 DIMENSIONS REV.1-09/09 2003 3368 1739...
  • Page 20 UNPACKING REV.1-02/04 NOTE + Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s pack- aging, 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 21: Moving Method

    Transport and handling REV.0-06/10 General precautions when handling the machine. Moving method The generating sets are lifted with different methods ac- cording to the unit’s configuration. Below are the main methods of moving/lifting the genset. ATTENTION Moving the generating set via forklift When lifting with a forklift it is necessary to fork the ba- When moving/lifting a genset it is imperative to be seframe sideways so that the forks stick out from one...
  • Page 22 Transport and handling 4.2.1 REV.0-06/10 Moving the generating set via cables or chains Moving by site trolley / trailer Site tow CTL: 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 gene- this trailer is made by the manufacturer and connected rating set for which they were designed.
  • Page 23 Fuel fumes are highly toxic; carry out operations outdoors only, or in a well- RECOMMENDED OIL ventilated environment. MOSA recommends selecting AGIP engine oil. Avoid accidentally spilling fuel. Clean Refer to the label on the motor for the recommended any eventual leaks before starting up products.

  • Page 24: Cooling Liquid

    Set-up for operation Water cooled systems REV.1-02/11 GROUNDING CONNECTION COOLING LIQUID ATTENTION The grounding connection to an earthed installation is obligatory for all models equipped with a diffe- Do not remove the radiator tap with the rential switch (circuit breaker). In these groups the motor in operation or still hot, as the generator star point is generally connected to the liquid coolant may spurt out and cause...

  • Page 25: Check Daily

    START AND STOP (EP6) REV.0-02/06 Check daily 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, NOTE hour-meter, etc.
  • Page 26 CONTROLS LEGENDE REV.3-04/13 Hydraulic oil level light Exclusion indicating light PTO HI Selection push button 30 l/1' PTO HI Welding socket ( + ) Auxiliary current push button Battery voltmeter Welding socket ( - ) Fuel level light Remote control socket Earth terminal E.A.S. PCB Button indicating light 20 l/1' PTO HI A.C. socket Control unit for generating sets QEA Commutator/switch, serial/parallel Accelerator lever Thermal-magnetic circuit breaker Ground fault interrupter ( 30 mA ) Feed pump Selection push button 20 l/1' PTO HI Engine control unit and economiser 48V D.C. socket Water temperature indicator Engine air filter Ammeter Oil level dipstick Frequency meter Engine oil reservoir cap Frequency rpm regulator 24A Hydraulic oil reservoir cap Voltmeter regulator 24B Water filling cap Fuse Fuel prefilter Stop switch Fuel tank cap Warning light, high temperature Muffler...
  • Page 27 COMANDI BEDIENELEMENtE CONtROLS MANDOS GE 85 - 115 PSX COMMANDES REV.0-11/06...

  • Page 28: Front Panel

    PROTECTIONS EP6 ENGINE PROTECTION 39.12 REV.1-03/11 FRONT PANEL C) - In order to cancel the AUTO operating mode, push the AUTO pushbutton (the yellow Led will 4 digits DISPLAY turn OFF) or turn the KEY-SWITCH to OFF. [UP DOWN] Once in AUTO, the EP6 waits for a REMOTE Button START activation (see section 7.0).

  • Page 29: Operating Messages

    PROTECTIONS EP6 ENGINE PROTECTION 39.12. REV.1-03/11 5.0 LEDs for visual indication 4.0 ALARM messages The EP6 features two LEDs (see section 10.0) to The alarms are displayed by means of messages. indicate the following conditions: In case of alarm consult your Generating Set manu- facturer.
  • Page 30 PROTECTIONS EP6 ENGINE PROTECTION 39.12. REV.0-10/05 Display Parameter [Default] [P.0] 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 auto- matic engine start (see section 7.0 and [P20] in this section). [P.1] Remote Stop Delay Timing (Input #7) [ 1"] Range: 1-59 secs or 1-15 mins...
  • Page 31 PROTECTIONS EP6 ENGINE PROTECTION 39.12. REV.1-03/11 [P.17] Alarm Output Timing [ 1'] [inh.] 1-59 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.
  • Page 32 PROTECTIONS EP6 ENGINE PROTECTION 39.12. REV.1-03/11 7.0 REMOTE START The EP6 will start the engine after the programmed The EP6 features REMOTE START only in AUTO number of days and the engine will run for the pro- operating mode. grammed time. To determine how the Automatic To operate the REMOTE START, follow the instruc- Periodic Test is programmed enter the Reading tions.
  • Page 33 Using the generator REV.3-11/11 are the same. WARNING + In the absence of a load, the values for voltage and frequency can be greater than their nominal values. See It is absolutely forbidden to connect the unit sections on VOLTAGE and FREQUENCY. to the public mains and/or another electrical power source .
  • Page 34 Using the generator REV.1-09/05 The frequency, and therefore the number of motor SINGLE-PHASE LOADS revolutions, is maintained constant by the motor’s speed Power to monophase utilities by means of three-phase regulation system. generators requires some operating limitations. Generally, this regulator is of a mechanical type and - In single-phase operation, the declared voltage presents a droop from no-load to nominal load which tolerance can no longer be maintained by the regulator...

  • Page 35: Differential Switch

    Using the generator REV.1-09/05 DIFFERENTIAL SWITCH USAGE WITH EAS AUTOMATIC START-UP PANEL The differential switch or differential relay guarantee The electricity-generating group in combination with the protection against indirect contacts due to malfunction EAS automatic start-up panel forms a unit for distributing currents towards the ground.
  • Page 36 TCM 35 REMOTE CONTROL 38.6 REV.0-03/06 MAKE SURE  The selector LOCAL START/REMOTE START (I6) of the generating set must be switched on LOCAL- START.  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.
  • Page 37 BEWARE: this operation is allowed only under the responsibility of personnel able to activate different solutions to ensure electrical protection of the system powered by the gen-set. USE OF THE DER3 / 0D MODEL (MOSA SET UP) 1) Manual reset 2) Regulation of intervention time: INST (instantaneous) 3) Regulation of fault current: 30 mA 4) Output relay: N.De...
  • Page 38 PROTECTIONS INSULATION MONITORING 39.10 REV.1-11/14 LEGEND: NOTE 1 Adjustment of Alarm threshold 2 Set-alarm dip-switches Don not intervene on the setting of the protection 3 Led, pre-allarm indication switch. Before using the machine check the ON 4 Led , power indication warning lamp lighting.

  • Page 39: Operation

    Self-loading prearrangement 29.1 REV.0-06/10 OPERATION The generators can be supplied with the fuel auto- The operating mode is selected by means of a th- matic load kit. The kit includes: the pump, the fuel ree-position switch Aut-0-Man. level sensor (3 levels) and the control board. The kit does not include the pipes for the connection Manual Position - between the generator tank and the external tank...
  • Page 40 Self-loading prearrangement 29.1.1 REV.0-06/10 The following is a simplified diagram of the fuel feed circuit. The purpose of this diagram is only to provide guidance. The design and implementation of the entire system must be performed by qualified personnel familiar with the specific rules applica- ble to the installation site.
  • Page 41 3-WAY VALVE FUEL SYSTEM KIT 29.2 REV.0-07/10 This system allows to feed the motor of the genera- tor 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 connection of the hoses from the external tank.

  • Page 42: Troubleshooting

    Diesel engine 40.2 Troubleshooting REV.3-07/06 Problem Possible cause Solution ENGINE The motor does not start up 1) Start-up switch (I6) (where it is assembled) in 1) Check position incorrect position 2) Emergency button (L5) pressed 2) Unblock 3) Preheating (where it is assembled) 3) Lacking or insufficient preheating phase for sparkplugs.
  • Page 43 Troubleshooting Diesel engine 40.2. REV.4-03/11 Problem Possible cause Solution GENERATOR Absence of output voltage Voltage switch in position 0 Check position Voltage switch faulty Check connections and working of the switch, repair or replace Protection tripped due to overload Check the load connected and diminish Differential protection device tripped.

  • Page 44: Maintenance

    MAINTENANCE REV.1-06/10 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 45 MAINTENANCE 43.1 REV.0-06/10 IMPORTANT ATTENTION The information given in the table is only indicative. For the canopied machines there are rou- Specific instructions are given in the operation ma- tine maintenance operations that require nuals. The engine and alternator manufacturers indicate that the operator climbs on top of the ma- chine at a height higher than 2 m.
  • Page 46 MAINTENANCE 43.2 REV.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.

  • Page 47: Gasoline Engine

    STORAGE REV.0-06/07 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.
  • Page 48 CUST OFF REV.0-06/07 Have qualified personnel disassemble the In case of necessity for first aid and fire prevention, machine and dispose of the parts, including the see page M2.5. oil, fuel, etc., in a correct manner when it is to be taken out of service.

  • Page 49: Electrical System Legende

    ELECTRICAL SYSTEM LEGENDE REV.11-06/14 A : Alternator E3 : Open circuit voltage switch I6 : Start Local/Remote selector N9 : UP/DOWN button mast B : Wire connection unit F3 : Stop push-button L6 : Choke button O9 : Hydraulic unit solenoid valve C : Capacitor G3 : Ignition coil M6 : Switch CC/CV P9 : Hydraulic unit engine D : G.F.I. H3 : Spark plug N6 : Connector – wire feeder Q9 : Ignitor E : Welding PCB transformer I3 : Range switch O6 : 420V/110V 3-phase transformer...
  • Page 50 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 PSX 61.1 SCHEMAS ELECtRIquES REV.1-02/15...
  • Page 51 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 115 PSX 61.2 SCHEMAS ELECtRIquES REV.3-02/15...
  • Page 52 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 - 115 PSX 61.3 SCHEMAS ELECtRIquES GE 165 PS - PSX REV.1-02/15...
  • Page 53 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85-115 PMSX 61.4 SCHEMAS ELECtRIquES REV.1-02/15...
  • Page 54 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 - 115 PSX 61.5 SCHEMAS ELECtRIquES GE 165 PS - PSX REV.1-02/15...
  • Page 55 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 - 115 PSX 61.6 SCHEMAS ELECtRIquES GE 165 PS - PSX REV.1-02/15 G.F.I. RELAY 1 2 3 4 5 6 G.F.I. DOSSENA DER3/0D 7 8 9 10 11 12 ATTENZIONE: Scollegare ponticello per disabilitare G.F.I.
  • Page 56 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 - 115 PSX 61.7 SCHEMAS ELECtRIquES GE 165 PS - PSX REV.0-02/15...
  • Page 57 SCHEMA ELEttRICO StROMLAuFPLAN ELECtRIC DIAGRAM ESquEMA ELéCtRICO GE 85 - 115 PSX 61.8 SCHEMAS ELECtRIquES GE 165 PS - PSX REV.0-02/15...
  • Page 60 MOSA div. della BCS S.p.A. Viale Europa, 59 20090 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...

This manual is also suitable for:

Ge 115 psx

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