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Mosa TS 400 KS Use And Maintenance Manual

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USE AND MAINTENANCE MANUAL
TS 400 KS - KSX
M A D E
I N
I T A L Y
Codice
Code
374049003
Codigo
Kodezahl
Edizione
Edition
06.2014
Edición
Ausgabe

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Summary of Contents for Mosa TS 400 KS

  • Page 1 USE AND MAINTENANCE MANUAL Codice Code 374049003 Codigo TS 400 KS - KSX Kodezahl Edizione Edition 06.2014 Edición Ausgabe M A D E I T A L Y...
  • Page 3 DESCRIPTION OF THE MACHINE TS 400 KS - KSX REV.0-06/14 The TS 400 engine driven welder is a unit which ensures the function as: a) a current source for arc welding b) a current source for the auxiliary power generation It is meant for industrial and professional use, powered by an endothermic engine;...
  • Page 5 · Competent support in the solution of problems; ofthe International Certification Network IQNet, · Information and training in the correct applicatio- awarded the official approval to MOSA after an- nand use of the products to assure the security examination of its operations at the head office ofthe operator and protect the environment;...
  • Page 6 INDEX REV.3-04/14 M 01 QUALITY SYSTEM M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARK M 1.4.1 DECLARATION OF CONFORMITY M 1.5 TECHNICAL DATA M 1.6 TECHNICAL DATA ENGINE DRIVEN WELDER ADVICE M 2.1 SYMBOLS AND SAFETY PRECAUTIONS M 2.6 INSTALLATIONS AND ADVICE M 2.7 INSTALLATION...
  • Page 7 (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 8 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 9 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 10 Konformitätserklärung Dichiarazione conformità Declaration of conformity Declaración de conformidad 1.4.1 Déclaration de conformité Declaração de conformidade REV.2-10/13 BCS S.p.A. Stabilimento di Cusago, 20090 (Mi) - Italia V.le Europa 59 Sede legale: Tel.: +39 02 903521 Via Marradi 1 Fax: +39 02 90390466 20123 Milano - Italia DICHIARAZIONE DI CONFORMITA' Déclaration de Conformité...
  • Page 11 Technical data TS 400 KS - KSX REV.0-06/14 Technical data TS 400 KS TS 400 KSX ALTERNADOR Self-excited, self-regulated, brushless Type three-phase, asynchronous Insulating class GENERATOR Three-phase generation 13 kVA / 400 V / 18.7 A Single-phase generation 7 kVA / 230 V / 30.4 A Single-phase generation 3.5 kVA / 110 V / 31.8 A...
  • Page 12 Technical data TS 400 KS - KSX 1.5.1 REV.0-06/14 D.C. WELDING C.C. Service 400 A - 35%, 350 A - 60%, 300 A - 100% Welding current regulation (I Scale) 20 - 400A Arc Force regulation * 0 ÷ 9...
  • Page 13 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 14 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 15 PRECAUTION (ENGINE DRIVEN WELDER) 2-5- REV.0-03/00 INSTALLATION AND ADVICE BEFORE USE The operator of the welder is responsible for the security of the people who work with the welder and for those in the vicinity. The security measures must satisfy the rules and regulations for engine driven welders. The information given below is in addition to the local security norms.
  • Page 16 INSTALLATION AND ADVICE REV.1-06/07 Check that the air gets changed completely and the hot INSTALLATION AND ADVICE BEFORE USE air sent out does not come back inside the set so as to cause a dangerous increase of the temperature. GASOLINE ENGINES Use in open space, air swept or vent exhaust gases, which contain the deathly carbone oxyde, far from the work area.
  • Page 17 Installazione Luftzirkulation Installation Instalación TS 400 KS - KSX Installation REV.0-06/14...
  • Page 18 Abmessungen Dimensions Dimensiones TS 400 KS - KSX 2.7.1 Dimensions REV.0-06/14...
  • Page 19 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 20 TRANSPORT AND DISPLACEMENTS COVERED UNITS REV.1-06/10 NOTE Transportation must always take place with the engine off, electrical cables and starting battery disconnected and fuel tank empty. Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging, and conform to local rules and regulations.
  • Page 21 CTL400 ASSEMBLY REV.0-06/00 ATTENTION The CTL accessory cannot be removed from the machine and used separately (actioned manually or following vehicles) for the transport of loads or anyway for used different from the machine movements. TRAILERS The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a maximum speed of 40 Kms/hour on asphalted surfaces.
  • Page 22 LUBRICANT motor. RECOMMENDED OIL MOSA recommends selecting AGIP engine oil. Refill the tank with good quality diesel fuel, such as Refer to the label on the motor for the recommended automobile type diesel fuel, for example.
  • Page 23 ENGINE STARTING AND USE (DIESEL ENGINES) REV.0-06/99 ENGINES WITHOUT ACCELERATOR LEVER Check daily lnsert the electric protection device (D-Z2-N2) lever towards above and, where mounted, check the isolation monitor (A3) see page M37 – NOTE Introduce the key (Q1), turn it clockwi- START se completely, leaving it as soon as Do not alter the primary conditions of regulation...
  • Page 24 ENGINE STARTING AND USE (DIESEL ENGINES) 21.1 REV.0-06/99 ENGINE WITH PREHEATING GLOW PLUGS Turn the starter key (Q1) on the position "prehea- ting glow plugs" (the glow plugs light will be on I4), when the light is off, turn the starter key completely clockwise until the engine begins to fire.
  • Page 25 STOPPING THE ENGINE (DIESEL ENGINE) REV.0-10/00  Before stopping the engine it is compulsory to Remove the key (Q1) turning it counter clockwise, OFF position, then take it out. effect the following operations: START - stop to draw three/single-phase current from the auxiliary sockets.
  • 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 Controls Mandos TS 400 KS - KSX Commandes REV.0-06/14 (EP1 Version) E .P .1 LO W EN GI NE PR ES S. HIG H (48V Version)
  • Page 28 USE AS WELDER REV.0-10/99 This symbol (Norm EN 60974-1 security +Make sure that the ground clamp ,whose cable standards for arc welders ) signifies that the must be connected to the + or - terminal, de- welder can be used in areas with increased pending on the type of electrode, makes a risk of electrical shock.
  • Page 29 USE AS WELDER 34.1 REV.0-10/99 MACHINE WITH REDUCTION SCALE "CC/CV" MODELS SWITCH These models can be used with electrodes For small electrodes (up to Ø 3.25-130A or for TIG welding by selecting the CC 100% and 4-200A) it is recommended to use the (constant current) mode, and with solid reduction scale switch (I3) allowing a more wire (MIG, MAG) or flux cored wire...
  • Page 30 USE AS A GENERATOR REV.0-06/99 + It is strictly forbidden to connect the group + N.B.:if the warning light does not flash, check to the public mains a/o to another source of the accelerator which must bebat its ma- electric power. ximum, or the fuse of the relevant socket.
  • Page 31 USE AS A GENERATOR 37.1 REV.0-06/99 TS ... PL VERSION UNIT FITTED WITH GFI SWITCH THERMAL MA- GNETIC BREAKER Start the machine and wait for the end of the pre- heating time imposed by the EP1, EP2, EP5 engine protection device. - See pages M39... - Press the „generation possibility“...
  • Page 32 ACCESSORY USE REMOTE CONTROL TC2 / TC2/50 REV.1-06/05 PUSH AND SCREW TIGHT The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector. To regulate the current from the TC2 / TC2/50, move the switch (7), located above the multipole connector (8), to "ON"...
  • Page 33 USE AND MAINTENANCE ENGINE PROTECTION EP1 39.1 REV..1-10/05 ENGINE PROTECTION (EP1) The electronic device EP.1 (D1) is a microprocessor with logic-circuit board that ensures the protection D1.1(G) Low oil temperature/ of the engine in case of low oil pressure or engine Cold engine high temperature.
  • Page 34 USE OF THE PROTECTION ENGINE PROTECTION 39.4 ES - EV REV..1-04/03 ENGINE PROTECTION (ES - EV) The devices ES or EV ensure the protection of the engine in case of low oil pressure or engine high temperature. The system consist of electronic card of control High temperature and check, and of an engine stop device: solenoid (ElettroStop), electrovalve (ElettroValvola)
  • Page 35 TROUBLE SHOOTING 40.1 REV.0-04/04 PROBLEM POSSIBLE CAUSE WHAT TO DO No welding current but 1) Defective diode bridge 1) Check the diodes of the bridge auxiliary output is OK 2) Problem with welding current control 2) Is the remote control switch in the inter- (PCB) nal position? 3) Check the diodes and SCR’s of the...
  • Page 36 MAINTENANCE REV.1-01/13 WARNING ● 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 37 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 38 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 39 RECOMMENDED ELECTRODES (In accordance with A.W.S Standard) REV.0-10/03 The information here below are to be intended only as indicative since the above norm is much larger. For further details please see the specific norms and/or the manufacturers of the product to be used in the welding process.
  • Page 40 ELECTRICAL SYSTEM LEGENDE REV.10-05/13 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 41 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.1 Schemas electriques REV.0-06/14...
  • Page 42 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.2 Schemas electriques REV.0-06/14...
  • Page 43 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.3 Schemas electriques REV.0-06/14...
  • Page 44 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.4 Schemas electriques REV.0-06/14...
  • Page 45 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.5 Schemas electriques REV.0-06/14...
  • Page 46 Stromlaufplan Schema elettrico Electric diagram Esquema eléctrico TS 400 KS - KSX 61.6 Schemas electriques REV.0-06/14...
  • Page 48 WWW.MOSA.IT MOSA div. della BCS S.p.A. Stabilimento di Viale Europa, 59 20090 Cusago (MI) Italia Tel. + 39 - 0290352.1 Fax + 39 - 0290390466...

This manual is also suitable for:

Ts 400 ksx