Related Manuals for Mosa GE 85 FR-5-RENTAL
Summary of Contents for Mosa GE 85 FR-5-RENTAL
- Page 1 CN8U10G19003_EN 01-2024 Use and Maintenance Manual D5263260 Generating set GE 85 FR-5 - RENTAL GE 100 FR-5 - RENTAL 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 .........................10... - Page 4 Contents Electrical protection ..........................31 4.2.1 Main machine switch ......................31 4.2.2 Ground differential relay ......................31 4.2.3 Residual current circuit breaker with overcurrent protection (RCBO) ........32 4.2.4 Residual current circuit breaker ...................32 4.2.5 Insulation monitor ........................32 4.3 Optional fittings ..........................34 4.3.1 3-way kit for fuel supply .......................34 4.3.2 PAC-I mains/generator switchboard ..................35 Installation ............................37...
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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 data plate applied in the area indicated in the figure. They are necessary for spare parts requests and communications with the Customer Service Department. D5263270 Manufacturer 's data Machine data • Made In: Country and year of manufacture • TYPE: Model • SERIAL N°: Serial number • Generating Set ISO 8528: Technical standard reference Machine technical data •... -
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. GE 85 FR-5 GE 100 FR-5 D5263280 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 D5263720... -
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. 7 - Lifting points with forklift truck M840760202 • Pos. 8 - 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.
- Page 13 2. Safety • Pos. 13 - Battery disconnect switch BATTERY SWITCH MC1PN10430271...
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Page 14: 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 15: 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 caps tightly. -
Page 16: 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 17: 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 18: 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 19: 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 20: 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 21: Precautions When Using The Def (Adblue)
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 when using the DEF (AdBlue) The DEF (AdBlue) is a water-based solution used to reduced the quantity of atmospheric pollution created by a diesel engine. -
Page 22: Precautions When Disposing Of The Def (Adblue)
2. Safety 2.11 Precautions when disposing of the DEF (AdBlue) • Treat the DEF (AdBlue) and its container as industrial waste. • To dispose of it, use a resin (PP, PE) or stainless steel container. • There may be crystallized urea build-ups at the end of the drain pipe. Dispose of any crystallized urea and treat the dirty cloth as industrial waste. -
Page 23: Technical Data
3. Technical data Technical data Machine dimensions 2878 mm 2828 mm 385 mm 2100 mm 2931 mm 1170 mm 120 mm 980 mm 1220 mm D5263290... -
Page 24: Technical Data
3. Technical data Technical data 3.2.1 Mod. GE 85 FR-5 Rated power Three-phase stand-by power ( 3∼92.0 kVA (73.6 kW) / 400V / 132.8A Three-phase PRP power ( 3∼85.0 kVA (68.0 kW) / 400V / 122.7A Three-phase COP power ( 3∼74.0 kVA (59.2 kW) / 400V / 106.8A Frequency 50 Hz Cosφ General specifications Fuel tank capacity 400 ℓ Autonomy (75% PRP) 26 h DEF (AdBlue) tank capacity 43 ℓ... -
Page 25: Mod. Ge 100 Fr-5
3. Technical data 3.2.2 Mod. GE 100 FR-5 Rated power Three-phase stand-by power ( 3∼100.0 kVA (80.0 kW) / 400V / 144.3A Three-phase PRP power ( 3∼100.0 kVA (80.0 kW) / 400V / 144.3A Three-phase COP power ( 3∼82.0 kVA (65.6 kW) / 400V / 118.4A Frequency 50 Hz Cosφ General specifications Fuel tank capacity 400 ℓ Autonomy (75% PRP) 23.2 h DEF (AdBlue) tank capacity 43 ℓ... - Page 26 An overload of 10% is allowed for one hour every 12 hours. ) COP power = continuous power at constant load. Prime power available for use at constant load for an unlimited number of hours/year. Note For operations with other environmental conditions, contact MOSA Technical Service.
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Page 27: 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 D5263300... - Page 28 4. Description Control panel Control panel access door Electrical distribution panel with three-phase and single-phase output sockets Emergency button Quick couplings for external fuel tank (optional) Coolant drain plug Engine compartment access door Alternator compartment access door Fluid drain plug 10 - Fuel drain plug 11 -...
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Page 29: Internal Components
4. Description 4.1.2 Internal components D5263310 Alternator Engine 3 - Engine air filter Radiator cap Coolant expansion tank Base liquid leakage sensor Engine oil extraction pump Fuel tank cleaning access Fuel tank... - Page 30 4. Description D5263320 10 - Engine air filter clogging optical indicator 11 - Fuel filter 12 - Oil filter 13 - Battery disconnect switch 14 - Fuel tank cap 15 - Fuel pre-filter 16 - Battery 17 - Oil level dipstick 18 - Oil filler plug...
- Page 31 4. Description D5263330 19 - DEF (AdBlue) feeding module 20 - Engine coolant 3-way valve/pump 21 - Exhaust post-treatment unit (ATS) 22 - DEF (AdBlue) tank 23 - DEF (AdBlue) tank cap...
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Page 32: Standard (Eu) Control Panel Components
4. Description control panel components 4.1.3 Standard (EU) D5263340 Control panel power switch (ON-OFF) 1500 / 1800 RPM selector for manual regeneration (Diesel Particulate Filter) Command and control unit DPF (Diesel Particulate Filter) manual regeneration button Protection fuses Buzzer 7 - Ground differential relay Residual current circuit breaker with overcurrent protection (RCBO) (4P 63A - 300mA Type A) for three-phase 63A 400V sockets... -
Page 33: Dguv Control Panel Components
4. Description control panel components 4.1.4 DGUV D5263350 Control panel power switch (ON-OFF) 1500 / 1800 RPM selector for manual regeneration (Diesel Particulate Filter) Command and control unit DPF (Diesel Particulate Filter) manual regeneration button Protection fuses Buzzer Insulation monitor Residual current circuit breaker (4P 63A) for three-phase 63A 400V sockets Residual current circuit breaker (4P 300mA Type B) for three-phase 63A 400V sockets 10 -... -
Page 34: Electrical Panel
4. Description 4.1.5 Electrical panel D5263360 Engine circuit auxiliary devices (fuses and relays) 2 - Auxiliary terminal block for the following connections: - Global alarm - Remote start and stop - Connection to PAC-I switchboard Service switch 4 - Water heater and battery charge protection residual circuit breakers Battery charge Main machine switch Ground cable collector Power terminal block ECU interface board/ Control panel with connector for motor diagnostics 10 - Engine control module... -
Page 35: 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 36: 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 37 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 38: 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 39: 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 40 4. Description NOTES:...
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Page 41: Installation
5. Installation Installation WARNING • Before proceeding with the installation, carefully read section “2.6 Installation precautions” 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 42: 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 Generating set Recommended minimum size... -
Page 43: 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 44: Grounding With Isolation Monitor
5. Installation 5.4.2 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 45: 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. • Continuous operation at low load In general, all machinery (in particular those equipped with motors with after-treatment devic- es) must operate with a load (i.e. - Page 46 6. Operation The apparent power is the total power required for the load, given by the sum of the active power delivered by the engine (after the alternator has transformed the mechanical power into electrical power) and the Re- active Power (kVAR) delivered by the alternator. The rated value of the power factor is cos ϕ = 0.8.
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Page 47: Checks Before Start-Up
6. Operation Checks before start-up 1 - Check that the battery disconnect switch is turned ON. D5263390 2 - Check the oil, fuel, coolant and DEF (AdBlue) levels. 3 - Check that the engine compartment, radiator and battery access doors are locked. 4 - Check that there are no oil, fuel, coolant and DEF (AdBlue) leaks. - Page 48 6. Operation 3 - Press the start button (2) to launch the generating set start sequence. Note The start button only works in MAN mode. D5260451 D5263420 4 - Wait for the Timer (4) on control and command unit IL-4 AMF 9 to drop to 0 (zero). 5 - Press the GCB opening/closing button (5) to enable the main machine switch (3) closing.
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Page 49: Stopping The Generating Set
6. Operation 8 - Turn all residual current circuit breakers with overcurrent protection (RCBO) and the residual current circuit break- ers (7) that protect the utilities connected to the output sockets to ON. Note ◦ It is advisable not to set the switches of unused out- put sockets to ON. -
Page 50: Emergency Stop
6. Operation Emergency stop For an emergency stop, press the emergency button (9). To reset the button, turn it clockwise. D5263440 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: •... - Page 51 6. Operation Active regeneration (ACM) WARNING • During the active regeneration process, do not stop the engine and do not let it run idle (with- out load) to allow the filter to be completely cleaned and the process to be concluded. •...
- Page 52 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.
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Page 53: Scr (Selective Catalytic Reduction)
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 54: Egr/Dpf Inducement
6. Operation The elimination of unburned hydrocarbons takes a short time (15-20 minutes), and it occurs by heating up the exhaust system until it reaches approx. 300°C. WARNING • Wait for the end of the burn-off strategy before stopping the engine. Use the arrow keys on the control and command unit to display the engine unit info pages, and check that the value of the “SCR Catalyst”... -
Page 55: Def Technical Failure
6. Operation 6.6.6 DEF Technical failure In case of fault or malfunction in the DEF (AdBlue) injection system, this is detected and signalled by the engine control unit. The fault causes the engine performance to drop. The “SCR ERROR INDICATOR LIGHT” turns on, on the control and command unit, and an info page on the engine control unit shows the fault level: 1, 2,3 •... -
Page 56: Def Quality
6. Operation 6.6.7 DEF Quality There is a sensor detecting the liquid quantity inside the DEF (AdBlue) tank. Some of the causes that can generate this alarm include: • In the DEF (AdBlue), the urea percentage is lower or higher than 32.5% • Dust in the DEF (AdBlue) The alarm is detected and signalled by the engine control unit. The level 1 alarm is a warning. -
Page 57: Def Level
6. Operation 6.6.8 DEF Level There is a sensor detecting the liquid quantity inside the DEF (AdBlue) tank. The DEF (AdBlue) percentage can be seen on one of the ECU1 engine control unit info pages. C ari co D EF Tnk Level D PFS ootLoa d 144% A CM ongo in g... -
Page 58: 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 59 6. Operation Indicator light Active indi- Inactive Alarm Exit activated name cator light indicator light Red stop indicator AHI ECU Red indicator ECU RED INDICATOR lamp light LIGHT D5260480 D5260620 This alarm is activated when the control unit sends information that the red light of the control unit is acti- vated.
- Page 60 6. Operation Indicator light Active indi- Inactive Alarm Exit activated name cator light indicator light AHI ATT Error indicator ATT ERROR INDICA- SCR error indica- light TOR LIGHT tor light D5260560 D5260570 This alarm is activated when the control unit sends information that the ECU ATT SCR Error indicator light is activated.
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Page 61: 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 62: 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 63: 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 64: Def (Adblue)
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. D5263700 5 - After the top-up operations, run the engine for a short period, check the coolant level again and refill if neces-... -
Page 65: Checking And Cleaning The Engine Air Filter
7. Maintenance 2 - Remove the cap (2) and pour the DEF (AdBlue) into the tank. D5263650 Note • While fuelling up, check that the 100% value is not ex- ECU1 ceeded on the page, to avoid overfuelling the tank. C ari co D EF Tnk Level 3 - Refit the cap (2) and tighten securely. D PFS ootLoa d 144% A CM ongo in g... -
Page 66: 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 67: 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 68 7. Maintenance NOTES:...
- Page 70 MOSA div. della BCS S.p.A. Viale Europa, 59 20047 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...