Mosa GE 60 FSX-5 Use And Maintenance Manual
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Mosa GE 60 FSX-5 Use And Maintenance Manual

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CN9U00G19003_EN
01-2023
Use and Maintenance Manual
D5261840
Generating set
GE 60 FSX-5
Original instructions

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  • Page 1 CN9U00G19003_EN 01-2023 Use and Maintenance Manual D5261840 Generating set GE 60 FSX-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 Ground differential relay ......................26 4.2.3 Residual current circuit breaker with overcurrent protection (RCBO) ........27 4.2.4 Residual current circuit breaker ...................27 4.2.5 Insulation monitor ........................27 4.3 Optional fittings ..........................29 4.3.1 3-way kit for fuel supply .......................29 4.3.2 PAC-I mains/generator switchboard ..................30 Installation ............................31...

  • 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. D5261850 A - 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 • Hz: Rated frequency •...

  • 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. D5261860 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 D5261870...

  • 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 muffler free from objects such as rags, paper, cartons. • The high temperature of the muffler could cause the objects to burn and cause a fire. • Immediately stop the machine in case of malfunctions. Do not restart the machine without first identifying and solving the problem.

  • 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 2430 mm 2430 mm 1050 mm 1030 mm D5261880...

  • Page 22: Technical Data

    3. Technical data Technical data Rated power 60 kVA (48 kW) / 400V / 86.6A Three-phase stand-by power ( 60 kVA (48 kW) / 400V / 86.6A Three-phase PRP power ( Frequency 50 Hz Cosφ General specifications 200 ℓ Fuel tank capacity Autonomy (75% PRP) 18.5 h Protection IP 44 Maximum dimension on base 2430x1050x1487 Weight (Dry) 1360 kg Measured sound power L...

  • Page 23: Description

    4. Description Description The Generating Set is a machine that transforms mechanical energy, generated by an engine, into electrical energy through an alternator. Main components 4.1.1 External components D5261890...
  • 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 D5261900 Engine 13 - Oil level dipstick 14 - Oil filler plug Radiator cap Exhaust post-treatment unit (ATS) Alternator Tank 6 - Fuel pre-filter Battery disconnect switch Battery Base liquid leakage sensor 10 - Engine air filter 11 - Oil filter 12 - Fuel filter...
  • Page 26 4. Description D5261910 15 - Coolant expansion tank 16 - Fuel tank cleaning access 17 - ECU interface board/ Control panel with connector for motor diagnostics 18 - Engine control module...

  • Page 27: Control Panel And Electrical Panel Components

    4. Description 4.1.3 Control panel and electrical panel components Type A D5261920 1 - Control panel power switch (ON-OFF) 1500 / 1800 RPM selector for manual regeneration (Diesel Particulate Filter) DPF (Diesel Particulate Filter) manual regeneration button Command and control unit Protection fuses Buzzer Main machine switch 8 - Ground differential relay Power terminal block...
  • Page 28 4. Description Type B - version with sockets D5261930 1 - Control panel power switch (ON-OFF) 1500 / 1800 RPM selector for manual regeneration (Diesel Particulate Filter) DPF (Diesel Particulate Filter) manual regeneration button Command and control unit Protection fuses Buzzer Main machine switch 8 - Ground differential relay Power terminal block 10 -...
  • Page 29 4. Description D5261940 Engine circuit protection fuses Service switch Ground cable collector Power terminal block 5 - 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. 5 - Check that there is no flammable or dirty material around the exhaust pipe.
  • Page 42 6. Operation 3 - Turn the control panel power switch (2) ON. D5261980 4 - Press the start button (3) to launch the generating set start sequence. Note The start button only works in MAN mode. D5260450 5 - Before supplying a load, let the engine run for the time shown in the following table. Ambient temperature Time required ≤ -20°C...

  • 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 (1) to OFF (insertion lever downwards). D5261970 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 6. Operation When an active regeneration is carried out, the "ATT FILTER INDICATOR LIGHT" (1) on the control and • command panel switches on. Aftertreatment D5262060 • The duration of an active regeneration varies, from a minimum of 30 minutes to a maximum of 60 min- utes. At the end of the process, the "ATT FILTER INDICATOR LIGHT" (1) turns off. Note The regeneration ends after 60 minutes regardless of the result obtained in cleaning the filter. Forced manual regeneration (MCM) WARNING During the forced manual regeneration process, do not stop the engine to allow the filter to be •...
  • Page 46 6. Operation Activating the forced manual regeneration WARNING Forced regeneration should be executed only when requested by the control unit. Repeated • regenerations cause heavy engine oil contamination by fuel. • During regeneration, do not operate any command. 1 - Disconnect all connected loads and turn off the generating set. 2 - Check the fuel level and refuel if necessary to allow a complete regeneration process.
  • Page 47 6. Operation Service regeneration • Frequent use of the engine with no load or low loads could compromise the outcome of the regeneration processes described in the previous paragraphs. In this case, the system requires a service regeneration process. • This operation can only be performed by FPT Technical Support Centres with a service tool.

  • Page 48: 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 49 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 50 6. Operation NOTES:...

  • 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. The engine is equipped with an exhaust gas after-treatment system, which may a include diesel oxidation catalyst (DOC), and a diesel particulate filter (DPF).

  • 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. D5262020 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 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 out.
  • Page 58 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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