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Summary of Contents for Mosa GE 40 YSX-5
- Page 1 CF0T8G19003_EN 11-2022 Use and Maintenance Manual D5261240 Generating set GE 40 YSX-5 GE 50 YSX-5 Original instructions...
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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 4.1.3 Control panel and electrical panel components ..............24 Electrical protection ..........................27 4.2.1 Main machine switch ......................27 4.2.2 Residual current circuit breaker (present only on Type A panel) ......... 27 4.2.3 Ground differential relay (present only on Type B panel) ............ 27 4.2.4 Residual current circuit breaker with overcurrent protection (RCBO) (present only on Type B panel) 28 4.2.5 Isolation monitor (present only on Type B panel) ..............
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Page 5: Introduction
1. Introduction Introduction Foreword This manual supplies the Operator and qualified and authorised Technicians with technical information on the GE 40 YSX-5 and GE 50 YSX-5 generating set (hereinafter also referred to as the "machine") produced by MOSA Div. of BCS S.p.A. (hereinafter also referred to as the "manufacturer"). In this manual, the Operator in charge and the qualified Technicians will find the indications for: • Getting familiar with the safety measures and basic standards to be adopted, to prevent hazards and damage to people, to the generating set and to the environment. -
Page 6: Supplied Documentation
Spare parts Only original spare parts that guarantee functionality and durability must be used. The use of non-original spare parts will void all warranty and Technical Support obligations. Declaration of conformity The manufacturer: MOSA Div. of BCS S.p.A. Viale Europa, 59 20047 Cusago (Milano) Italy Declares that the machine: GE 40 YSX-5 GE 50 YSX-5 Complies with the requirements of the following EC/EU Directives: •... -
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. D5261250 A - Manufacturer 's data B - 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. D5261260 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 D5261270... -
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.
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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. • The machine can only be used and repaired by trained and authorized personnel. -
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. • • Do not discharge the oil directly into the soil or sewage system, rivers, seas or lakes. -
Page 21: Technical Data
3. Technical data Technical data Machine dimensions (mod. GE 40 YSX - GE 50 YSX) 2050 mm 900 mm D5261280... -
Page 22: Machine Dimensions (350 Litre Version)
3. Technical data Machine dimensions (350 litre version) 2050 mm 900 mm D5261290... -
Page 23: Technical Data (Mod. Ge 40 Ysx)
3. Technical data Technical data (mod. GE 40 YSX) Rated power 38 kVA (30.4 kW) / 400V / 54.8A Three-phase stand-by power ( 34 kVA (27.2 kW) / 400V / 49A Three-phase PRP power ( Frequency 50 Hz Cosφ General specifications 100 ℓ Fuel tank capacity 350 ℓ (upon request) 100 ℓ 17 h Autonomy (75% PRP) 350 ℓ 59 h Protection IP 44 100 ℓ... -
Page 24: Technical Data (Mod. Ge 50 Ysx)
3. Technical data Technical data (mod. GE 50 YSX) Rated power 46 kVA (36.8 kW) / 400V / 66.4A Three-phase stand-by power ( 42 kVA (33.6 kW) / 400V / 60.6A Three-phase PRP power ( Frequency 50 Hz Cosφ General specifications 100 ℓ Fuel tank capacity 350 ℓ (upon request) 100 ℓ 14 h Autonomy (75% PRP) 350 ℓ 48.5 h Protection IP 44 100 ℓ... -
Page 25: 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 D5261300... - Page 26 4. Description Control panel Control panel access door Electrical distribution panel Rain cover for exhaust pipe Lifting hook Radiator cap access door 7 - Oil drain plug Coolant drain plug Fluid drain plug 10 - Engine compartment access door 11 - Battery compartment access door 12 - Liquid sealed base 13 - Radiator compartment panel...
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Page 27: Internal Components
4. Description 4.1.2 Internal components D5261340 Fuel tank Alternator Exhaust post-treatment unit (ATS) 4 - Oil level dipstick 5 - Engine air filter 6 - Oil filter 7 - Fuel filter Radiator cap Coolant expansion tank 10 - Oil filler plug 11 - Fuel pre-filter 12 - Fuel filler plug 13 - Fuel supply pump 14 - Base liquid leakage sensor 15 - Battery 16 - Battery disconnect switch... -
Page 28: Control Panel And Electrical Panel Components
4. Description 4.1.3 Control panel and electrical panel components Type A - STD version D5261310 DPF (Diesel Particulate Filter) manual regeneration button PCD indicator light (engine fault) 3 - Control panel power switch (ON-OFF) 4 - NCD indicator light (exhaust post-treatment system fault) Command and control unit ACK indicator light (DPF - Diesel Particulate Filter - manual regeneration enable) Protection fuses Residual current circuit breaker Main machine switch... - Page 29 4. Description Type B - Version with electrical distribution panel D5261320 DPF (Diesel Particulate Filter) manual regeneration button PCD indicator light (engine fault) 3 - Control panel power switch (ON-OFF) 4 - NCD indicator light (exhaust post-treatment system fault) Command and control unit ACK indicator light (DPF - Diesel Particulate Filter - manual regeneration enable) Protection fuses 8 - Residual current circuit breaker with overcurrent protection (RCBO) (2P 16A - 30mA Type A) for sin-...
- Page 30 4. Description D5261330 1 - Auxiliary terminal block for the following connections: - Global alarm - Remote start and stop - Connection to PAC-I switchboard Engine circuit fuses and relays Service switch Engine control module...
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Page 31: 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 32: Residual Current Circuit Breaker With Overcurrent Protection (Rcbo) (Present Only On Type B Panel)
4. Description DER3/ 0D model factory settings • Microswitches Output relay: N.De (Normally de-energized) • Fault current adjustment: IΔ : x 0.1 • Intervention time adjustment: t : x 1 • Reset: Man. (manual) • • Potentiometers IΔ (A) : 0.3 ÷ 0.5 (30mA ÷ 50mA) T(sec) : INST (Instant) 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 33 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.
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Page 34: 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 35: 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 36 4. Description NOTES:...
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Page 37: 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 38: 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 39: 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. -
Page 40: 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 41: 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 42 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.
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Page 43: Checks Before Start-Up
6. Operation Checks before start-up 1 - Check that the battery disconnect switch is turned ON. D5261360 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 44 6. Operation 3 - Turn the control panel power switch (2) ON. D5261380 4 - Press the start button (3) to launch the generating set start sequence. Note: The start button only works in MAN mode. D5260450 5 - The engine control module checks the operation of all Aftertreatment indicator lights on the control panel (4) and of all the engine control indicator lights (5).
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Page 45: Stopping The Generating Set
6. Operation 9 - Set the main machine switch (1) to ON (insertion lever upwards). 10 - Turn all residual current circuit breakers with overcur- rent protection (RCBO) and the residual current circuit breakers (6) that protect the utilities connected to the output sockets to ON. Note: • It is advisable not to set the switches of unused output sockets to ON. Before powering the utilities, check that the values of •... -
Page 46: Emergency Stop
6. Operation Emergency stop For an emergency stop, press the emergency button (8). To reset the button, turn it clockwise. D5261401... -
Page 47: 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 48 6. Operation Reset regeneration DANGER During reset regeneration, post-injection is employed, and fuel is burned directly within the DPF filter (through the chemical reaction occurring within the DOC catalyst). The exhaust temperature is very high (up to 600°C). Take the following precautions: Make sure that there are no people, animals or flammable material nearby and that the place is •...
- Page 49 6. Operation Forced manual regeneration (static) Even if the DPF filter executes the regeneration command, if unladen or low-load operating conditions are frequently repeated, the filter regeneration does not occur. When the DPF pollution level reaches 100% or higher, the engine control module requires a forced manual regeneration. The buzzer triggers and the control panel shows the following conditions: ECU light indicator light (1) ON and flashing • ATT filter indicator light (2) ON. • Aftertreatment D5261410 ACK indicator light (3) ON and flashing • PCD indicator light (4) ON. • D5261420 Important If indicator lights (1), (2) and (4) turn ON and indicator light (3) remains OFF, it means that the engine • requires a regeneration, but the regeneration conditions are not met (e.g., due to the presence of an engine alarm, or the coolant temperature lower than 60°C).
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Page 50: Activating The Forced Manual Regeneration (Static)
6. Operation Activating the forced manual regeneration (static) DANGER Before starting the DPF regeneration procedure, make sure that there are no people, animals or • flammable material nearby and that the place is well ventilated. Remove all flammable material that may be present around the machine such as dry leaves or •... - Page 51 6. Operation ◦ The ECU yellow indicator light (5) and the ATT filter indicator light (6) turn OFF. ◦ The high temperature indicator light (7) turns ON. Aftertreatment 4 - After about 30 minutes, the ACK indicator light (3) and the high temperature indicator light (7) turn OFF. 5 - At the end of the forced regeneration process, leave the engine ON at low speed, unladen, for about 5 minutes, to cool the filter down. D5261411 DPF maintenance WARNING Maintenance, removal and disposal of accumulated ash must be performed by specialised •...
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Page 52: 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 53 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 54 6. Operation NOTES:...
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Page 55: 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 56: 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 57: 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 58: 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. D5261460 4 - Refit the cap (2) and tighten securely. -
Page 59: 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 60: Maintenance Of Generating Sets With Automatic Intervention System
7. Maintenance Check DPF and DOC • • Check air intake valve operation • Check discharge power valve operation • Check and clean injectors 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 62 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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