ts 300 sc-sxc - mark one hire · we wish to thank you for having bought from mosa a high quality...
TRANSCRIPT
TS 300 SC-SXC
USE AND MAINTENANCE MANUALSPARE PARTS CATALOG
219829003 - GB1 2 0 5
21982M00 29/01/98preparato da UPTapprovato da DITE
Quality system GE_, MS_, TS_, EAS_M01
© MOSA 1.2-05/03
UNI EN ISO 9001 : 2000
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MOSA has certified its quality system according toUNI EN ISO 9001:2000 to ensure a constant, highquality of its products. This certification covers thedesign, production and servicing of engine drivenwelders and generating sets.
The certifying institute, ICIM, which is a member ofthe International Certification Network IQNet,awarded the official approval to MOSA after anexamination of its operations at the head office andplant in Cusago (MI), Italy.
This certification is not a point of arrival but a pledgeon the part of the entire company to maintain a levelof quality of both its products and services whichwill continue to satisfy the needs of its clients, aswell as to improve the transparency and thecommunications regarding all the company’s activesin accordance with the official procedures and inharmony with the MOSA Manual of Quality.
The advantages for MOSA clients are:
· Constant quality of products and services at thehigh level which the client expects;
· Continuous efforts to improve the products andtheir performance at competitive conditions;
· Competent support in the solution of problems;
· Information and training in the correct applicationand use of the products to assure the security ofthe operator and protect the environment;
· Regular inspections by ICIM to confirm that therequirements of the company’s quality systemand ISO 9001 are being respected.
All these advantages are guaranteed by theCERTIFICATE OF QUALITY SYSTEM No.0192issued by ICIM S.p.A. - Milano (Italy ) - www.icim.it
INDEX GE_, MS_, TS_, EAS_M1
© MOSA 1.0-01/01
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INDEX (for all MOSA models)
M 01 QUALITY SYSTEMM 1.01 COPYRIGHTM 1.1 NOTESM 1.4 NOTESM 2- ... SYMBOLS AND SAFETY PRECAUTIONSM 2.3 ABBREVIATIONS LEGENDM 2.4 SYMBOLSM 2.5... INSTALLATION AND ADVICE BEFORE USEM 2.6 INSTALLATIONS AND ADVICEM 2.7 INSTALLATIONM 3 PACKINGM 4 TRANSPORT AND DISPLACEMENTSM 6 ASSEMBLY: CT........M 20 SETTING-UP THE UNIT (DIESEL ENGINE)M 21 ENGINE STARTING AND USE (DIESEL ENGINE)M 22 STOPPING THE ENGINE (DIESEL ENGINE)M 25 SETTING-UP THE UNIT (GASOLINE ENGINE)M 26 STARTING THE ENGINE (GASOLINE ENGINE)M 27 STOPPING THE ENGINE (GASOLINE ENGINE)M 30 CONTROLS LEGENDM 31 CONTROLSM 32 CONTROLS (FRONT PANEL)M 33 USE AS HYDRAULIC POWER TAKE-OFF only for TSM 34 USE AS A WELDER only for TSM 35 USE AS AN ENGINE STARTER only for TSM 36 USE AS A BATTERY CHARGEM 37 USE AS A GENERATORM 38 USE OF THE REMOTE CONTROLM 39 USE OF THE ENGINE PROTECTIONM 40 TROUBLE SHOOTINGM 43 MAINTENANCEM 44 PERIODIC MAINTENANCEM 45 STORAGEM 46 CAST OFFM 51 TECHNICAL DATAM 52 TECHNICAL DATA ENGINE DRIVEN WELDER only for TSM 53 DIMENSIONSM 55 RECOMMENDED ELECTRODES only for TSM 60 ELECTRICAL SYSTEM LEGENDEM 61 ELECTRICAL SYSTEMM 65 HYDRAULIC SYSTEM
R 1 SPARE PARTS LIST...... SPARE PARTS
K... ACCESSORIES
Copyright GE_, MS_, TS_, EASM
1.01© MOSA 1.0-10/02
ATTENTION
� 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 thedocumentation are registered by the respectiveowners.
➠ The reproduction and total or partial use, inany form and/or with any means, of thedocumentation is allowed to nobody without awritten permission by MOSA division of B.C.S.S.p.A.
To this aim is reminded the protection of the author’sright and the rights connected to the creation anddesign for communication, as provided by the lawsin force in the matter.
In no case MOSA division of B.C.S. S.p.A. will beheld responsible for any damaga, direct or indirect,in relation with the use of the given information.
MOSA division of B.C.S. S.p.A. does not take anyresponsibility about the shown information on firmsor individuals, but keeps the right to refuse servicesor information publication which it judges discutible,unright or illegal.
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This use and maintenance manual is an importantpart of the machines in question.The assistance and maintenance personel mustkeep said manual at disposal, as well as that forthe engine and alternator (if the machine issynchronous) and all other documentation about themachine.
We advise you to pay attention to the pagesconcerning the security (see page M1.1).
INFORMATION
Dear Customer,We wish to thank you for having bought fromMOSA a high quality set.
Our sections for Technical Service and SpareParts will work at best to help you if it werenecessary.
To this purpose we advise you, for all control andoverhaul operations, to turn to the nearestauthorized Service Centre, where you will obtaina prompt and specialized intervention.
☞ In case you do not profit on these Services andsome parts are replaced, please ask and besure that are used exclusively original MOSAparts; this to guarantee that the performancesand the initial safety prescribed by the norms inforce are re-established.
☞ The use of non original spare parts will cancelimmediately any guarantee and Technical Ser-vice obligation from MOSA.
NOTES ABOUT THE MANUALBefore actioning the machine please read thismanual attentively. Follow the instructionscontained in it, in this way you will avoidinconveniences due to negligence, mistakes orincorrect maintenance. The manual is for qualifiedpersonnel, who knows the rules: about safety andhealth, installation and use of sets movable aswell as fixed.
You must remember that, in case you havedifficulties for use or installation or others, ourTechnical Service is always at your disposal forexplanations or interventions.
The manual for Use Maintenance and Spare Partsis an integrant part of the product. It must be keptwith care during all the life of the product.In case the machine and/or the set should beyielded to another user, this manual must alsogiven to him.Do not damage it, do not take parts away, do nottear pages and keep it in places protected fromdampness and heat.
You must take into account that some figurescontained in it want only to identify the describedparts and therefore might not correspond to themachine in your possession.
INFORMATION OF GENERAL TYPE
In the envelope given together with the machineand/or set you will find: the manual for UseMaintenance and Spare Parts, the manual foruse of the engine and the tools (if included in theequipment), the guarantee (in the countries whereit is prescribed by law).
Our products have been designed for the use ofgeneration for welding, electric and hydraulicsystem; ANY OTHER DIFFERENT USE NOTINCLUDED IN THE ONE INDICATED, relievesMOSA from the risks which could happen or,anyway, from that which was agreed when sellingthe machine; MOSA excludes any responsibilityfor damages to the machine, to the things or topersons in this case.
Our products are made in conformity with thesafety norms in force, for which it is advisable touse all these devices or information so that theuse does not bring damage to persons or things.
While working it is advisable to keep to thepersonal safety norms in force in the countries towhich the product is destined (clothing, work tools,etc.).
Do not modify for any motive parts of the machine(fastenings, holes, electric or mechanical devices,others..) if not duly authorized in writing by MOSA:the responsibility coming from any potentialintervention will fall on the executioner as in facthe becomes maker of the machine.
Notes GE_, MS_, TS_, EAS_M
1-1© MOSA 1.0-10/02
☞ Notice: this manual does not engage MOSA,who keeps the faculty, apart the essentialcharacteristics of the model here described andillustrated, to bring betterments and modificationsto parts and accessories, without putting thismanual uptodate immediately.
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CE MARK GE_, MS_, TS_, EAS_M
1.4© MOSA 1.2-06/03
The CE mark (European Community) certifies that the product complies with the essentialsafety requirements provided by the applicable COMMUNITY DIRECTIVES. In the ConformityDeclaration are reported the HARMONIZED NORMS and not, used for the checking.
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SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_M2
© MOSA 1.0-11/99
SYMBOLS IN THIS MANUAL
- The symbols used in this manual are designed to callyour attention to important aspects of the operation ofthe machine as well as potential hazards and dangersfor persons and things.
IMPORTANT ADVICE
- Advice to the User about the safety:
☞ N.B.: The information contained in the manual canbe changed without notice.Potential damages caused in relation to the use ofthese instructions will not be considered becausethese are only indicative.Remember that the non observance of theindications reported by us might cause damage topersons or things.It is understood, that local dispositions and/or lawsmust be respected.
WARNING
Situations of danger - no harm to personsor things
Do not use without protective devices providedRemoving or disabling protective devices on themachine is prohibited.
Do not use the machine if it is not in good technicalconditionThe machine must be in good working order beforebeing used. Defects, especially those which regardthe safety of the machine, must be repaired beforeusing the machine.
SAFETY PRECAUTIONS
This heading warns of an immediate danger for personsas well for things. Not following the advice can result inserious injury or death.
This heading warns of situations which could result ininjury for persons or damage to things.
To this advice can appear a danger for persons as well asfor things, for which can appear situations bringing mate-rial damage to things.
These headings refer to information which will assis youin the correct use of the machine and/or accessories.
!ATTENTION!
NOTE!
IMPORTANT!
CAUTION!
WARNING!
DANGEROUS!
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SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_M
2-1© MOSA 1.1-04/03
SYMBOLS (for all MOSA models)
STOP - Read absolutely and be duly attentive
Read and pay due attention
GENERAL ADVICE - If the advice is notrespected damage can happen to persons orthings.
HIGH VOLTAGE - Attention High Voltage.Therecan be parts in voltage, dangerous to touch.The non observance of the advice implies lifedanger.
FIRE - Danger of flame or fire. If the advice isnot respected fires can happen.
HEAT - Hot surfaces. If the advice is notrespected burns or damage to things can becaused.
EXPLOSION - Explosive material or danger ofexplosion. in general. If the advice is notrespected there can be explosions.
WATER - Danger of shortcircuit. If the adviceis not respected fires or damage to personscan be caused.
SMOKING - The cigarette can cause fire orexplosion. If the advice is not respected firesor explosions can be caused.
ACIDS - Danger of corrosion. If the advice isnot respected the acids can cause corrosionswith damage to persons or things.
WRENCH - Use of the tools. If the advice isnot respected damage can be caused to thingsand even to persons.
PRESSION - Danger of burns caused by theexpulsion of hot liquids under pressure.
PROHIBITIONS No harm for persons
Use only with safety clothing -
It is compulsory to use the personalprotection means given in equipment.
Use only with safety clothing -It is compulsory to use the personal protectionmeans given in equipment.
Use only with safety protections -It is a must to use protection means suitable forthe different welding works.
Use with only safety material -It is prohibited to use water to quench fires onthe electric machines.
Use only with non inserted voltage -It is prohibited to make interventions beforehaving disinserted the voltage.
No smoking -It is prohibited to smoke while filling the tankwith fuel.
No welding -It is forbidden to weld in rooms containingexplosive gases.
ADVICE No harm for persons and things
Use only with safety tools, adapted to the specificuse -It is advisable to use tools adapted to the variousmaintenance works.
Use only with safety protections, specifically suitableIt is advisable to use protections suitable forthe different welding works.
Use only with safety protections -It is advisable to use protections suitablefor the different daily checking works.
Use only with safety protections -It is advisable to use all protections whileshifting the machine.
Use only with safety protections -It is advisable to use protections suitable forthe different daily checking works.and/or ofmaintenance.
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ACCES FORBIDDEN to non authorizad peaple.
ABBREVIATIONS LEGEND GE_, MS_, TS_M
2.3© MOSA 1.0-06/99
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°C: temperature Celsius grades10:10 kVA synchronous (wording example)10000:10 kVA asynchronous (wording example)A: AmpereA: ADIM engineatm: pressureB: pretrolBAT: batteryBC: base currentC.A.(c.a.): alternating currentC.B.: battery chargerC.C.(c.c.): direct currentcc: cm³ (volume)CE: European norm conformityCF: special for pipe weldingCTL: slow touring trolleyCTM CTV: fast touring trolley: hand touring trolleyD: dieselD: GFID: Deutz engineE: electric startEAS: automatic intervention panel for generating sets forconnection to the mainsEL: electronic regulation, allows to use welder andgenerating set simultaneauslyEP1: automatic accelerator according to requestedpower,engine protection, low oil pressure, high temperaturewith engine stop, troble warning lightsEP2: engine protection, low oil pressure, hight temperaturewith engine stop, trouble warning lightsEP4: engine protection, low oil pressure, high temperaturewith engine stop, no battery charge, belt broken, low fuellevel with engine stop, trouble warning lightsEP5: engine protection, low oil pressure, high temperaturewith engine stop, no battery charge, belt broken, low fuellevel with engine stop, everspeed, trouble warning lightsEP6: Control and protection unit of generating sets. Ithas operating modes OFF – MAN – AUTO It protects theengine for low oil pressure, high temperature, belt broken,no battery charge and low fuel level, over peed andunder speed, over and under voltage and no tarting.Itshows besides: voltage, frequency and current generator,current battery voltage and battery charge, engine rpm.EP6 disposes of 29 programmable parameters.ES: oil/temperature engine protection deviceEV: electrovalveg/kwh: grams/kilowatt hour (engine consumption)GA: asynchronous alternatorGE: generating setGHF: high frequency alternatorGS: synchronous alternatorh: hour meter (symbol)H: Hatz engineH: Honda engineHI: hydraulic centralHz: frequencyI: single-phase auxiliary generation (symbol 1~)
IP: protection grads for electric devices against acess todangerous parts according to the IEC 529 norm (InternalProtection)kg: kilogram (mass)K: welding cables setkVA: kilovolt amperekW: kilowatt (engine power)kWh: kilowatt hour (energy)l: liters (capacity)L: Lombardini engineLwa: maximum acoustic (power level) according to theregulations in forcemm: millimeter (length) (measure)m: meter (length)mA: milliampereMS-MSG: MOSA engine driven welder with highfrequency alternatorMT: magnetothermic switchMT: grounding kitMTD: magnetothermic switch / GFIOH: heater (engine oil) for generating setsP: plusPAC: power electric framePAR: device for doublePB: battery holderPL: „pipe line“ weldingPS: exhaust pipe extensionPW: welder for polyethylene and propylene pipesQEA: automatic electric panelQEM: manual electric panelR: Ruggerini engineRVT: voltage electronic regulatorS: symbol of EN 60974-1S: Suzuki mengineotoreSKID: unit assembled on a base with no protection (nofairing)S-SC: silenced (faired) - silenced compact (fairedSX-SXC: supersilenced (faired and sound prof) -supersilenced compact (faired and super sound prof)T: thermic switchTC-TCM-TCPL: remote controlTS: welder with asynchronous alternatorV: VoltY: Yanmar engineY: three-phase auxiliary generation (symbol 3~)
SYMBOLS GE_, MS_, TS_, DSP_M
2.4© MOSA 1.1-04/05
ConformityCE
Singlephase1 ~
EECSound powerconformity
Triphase3 ~
EN 60974-1conformity
Equipment and optional
Engine
Centrallifting eye
Aircooling
Dieselengine
Electricstart
Asynchronousalternator
Socket400/230V
EEC
Socket230/110/48V
EEC
Polarityinverter
Base currentdiode bridge
Welding cur-rent electr.regulation
Batterycharger
indicator
Air filterblockage
Hourcounter
Socket48V EEC
Gasolineengine
Manualrecoil
Battery12 V
Batterycharger
Oil levelindicator
Thermalshut off
Synchronousalternator
Ground faultinterrupter
Watercooling
Low fuelindicator
Warning lightfor preheating
glow plugs
Circuitbreaker
Isolationmonitoring
Voltmeter
Arccontrol
Enginebooster
Fuse
Generatorhigh frequency
Weldingcables
Frequency-meter
Voltmeterphase
selector
Ammeter Compound
Terminalstrip
Remotecontrol
Welding withcovered
electrode
Generation
Generationuse
Weldingcontrol
Engineprotection
Socket230V
Schuko
Variousnews
Fuel levelgauge/low
fuel
Enginealarms
Electricprotection
Information
Switch
CC/CVselector
Ready for TC
Groundconnection
point
Emergencystop button
Options onrequest
Standardequipment
Trolley
Users'manual
Engineprotection
Engineprotection
Engineprotection
Siren Enginespeed
Engine shutdown (oil)
Engineprotection
Oiltemperature
Beltbreakage
Over speed Control unitQEA
ElectronicVoltage
regulator
Circuit breaker/Ground faultinterrupter
Variousdevices
Optionals
Various
Site tow
MaintenanceTime
+ -~A.C. Plus MinusD.C.
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E VE V ES EP1 EP5
RVT
MTD
+
-
+
-
Costantcurrent
Costantvoltage
TIG
Contactstarting
Engineprotection
INSTALLATION AND ADVICE BEFORE USE GE_, MS_, TS_M
2-5© MOSA 1.0-06/00
Stop engine when fueling
EN
GIN
E
CH
EC
KIN
G B
OA
RD
Do not touch electric devices if youare barefoot or with wet clothes.
Always keep off leaning surfacesduring work operations
Static electricity can demage theparts on the circuit.
An electric shock can kill
The installation and the general advice concerning the operations, are finalized to the correct use of themachine, in the place where it is used as generator group and/or welder.
!
☞ FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gasor whatever event which may cause serious injuries or death, predispose the first aid in accordance withthe ruling labour accident standards or of local instructions.
Skin contactEyes contactIngestionSuction of liquids fromlungsInhalation
Wash with water and soapIrrigate with plenty of water, if the irritation persists contact a specialistDo not induce vomit as to avoid the intake of vomit into the lungs, send for a doctorIf you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take thesubject to the hospital with the utmost urgencyIn case of exposure to high concentration of vapours take immediately to a non polluted zonethe person involved
☞ FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable tocause severe wounds or death, follow the first aid as described by the ruling norms or local ones.
AppropriatedNot to be usedOther indications
Particular protectionUseful warnings
Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized waterAvoid the use of water jetsCover eventual shedding not on fire with foam or sand, use water jets to cool off thesurfaces close to the fireWear an autorespiratory mask when heavy smoke is presentAvoid, by appropriate means to have oil sprays over metallic hot surfaces or over electriccontacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep inmind that the inflamability point is very low.
EXTINCTION MEANS
WARNING! CAUTION!
!
DA
NG
ERO
US
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WARNINGTHE MACHINE MUST NOT BE USED IN AREAS WITH
EXPLOSIVE ATMOSPHERE
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Do not smoke, avoid flames, sparks or electric tools when fueling.
Unscrew the cap slowly to let out the fuel vapours.
Slowly unscrew the cooling liquid tap if the liquid must be topped up.
The vapor and the heated cooling liquid under pressure can burn face, eyes, skin.
Do not fill tank completely.Wipe up spilled fuel before starting engine.Shut off fuel of tank when moving machine (where it is assembled).Avoid spilling fuel on hot engine.Sparks may cause the explosion of battery vapours
PRECAUTION (ENGINE DRIVEN WELDER) GE_, MS_, TS_M
2-5-1
© MOSA 1.0-03/00
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 thevicinity.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.
Estimate possible electromagnetic problems in the work area taking into account the following indications.1. Telephonic wirings and/or of communication, check wirings and so on, in the immediate vicinity.2. Radio and television receptors and transmettors.3. Computer and other checking devices.4. Critical devices for safety and/or for industrial checks.5. Peapol who, for instance, use pace-maker, hearing-aid for deaf or something and else.6. Devices used for rating and measuring.7. The immunity of other devices in the operation area of the welder. Make sure that other used devices are
compatible. If it is the case, provide other additional measures of protection.8. The daily duration of the welding time.
ATTENTION!
+ =
Make sure that the area is safe before starting any welding operation.
➠ Do not touch any bare wires, leads or contacts as they may be live and there is danger of electric shockwhich can cause death or serious burns. The electrode and welding cables, etc. are live when the unit isoperating.
➠ Do not touch any electrical parts or the electrode while standing in water or with wet hands, feet or clothes.
➠ Insulate yourself from the work surface while welding. Use carpets or other insulating materials to avoidphysical contact with the work surface and the floor.
➠ Always wear dry, insulating glovers, without holes, and body protection.
➠ Do not wind cables around the body.
➠ Use ear protections if the noise level is high.
➠ Keep flamable material away from the welding area.
➠ Do not weld on containers which contain flamable material.
➠ Do not weld near refuelling areas.
➠ Do not weld on easily flamable surfaces.
➠ Do not use the welder to defrost (thaw) pipes.
➠ Remove the electrode from the electrode holder, when not welding.
➠ Avoid inhaling fumes by providing a ventilation system or, if not possible, use an approved air breather.
➠ Do not work in closed areas where there is no fresh air flow.
➠ Protect face and eyes (protective mask with suitable dark lens and side screens), ears and body (non-flamable protective clothers).
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INSTALLATION AND ADVICE GE_, MS_, TS_M
2.6© MOSA 1.0-11/99
INSTALLATION AND ADVICE BEFORE USE
GASOLINE ENGINES■ Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far fromthe work area.
DIESEL ENGINES■ Use in open space, air swept or vent exhaust gases
far from the work area.
POSITIONPlace the machine on a level surface at a distance of atleast 1,5 m from buildings or other plants.
Check that the air gets changed completely and the hotair sent out does not come back inside the set so as tocause a dangerous increase of the temperature.
☞ Make sure that the machine does not move duringthe work: block it possibly with tools and/or devicesmade to this purpose.
Protect all the electric parts at risk, because waterinfiltrations could cause short circuits with damagesat persons and/or things.
The protection degree of the machine is put on the dataplate and in this manual at page "Technical Data".
Maximum leaning of the machine (in case of dislevel)
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1,5m
1,5m
1,5
m
GASDI SCARIC
O
EXHAUST OUTPUT
MOVES OF THE MACHINE☞ At any move check that the engine is off, that there
are no connections with cables which impede themoves.
PLACE OF THE MACHINE
In spots where it often rains and/or there areflooded areas, do not put the machine:■ in the bad weather■ in flooded places.
InstallazioneInstallationInstallation
TS 250-300 SC/SXCM
2.7© MOSA 1.0-12/05
LuftzirkulationInstalaciónE
D
NL
SUPERFICIE CALDAHOT SURFACESURFACE TRES CHAUDEHEIßER BEREICHSUPERFICIE CALIENTE Scarico silenziatore motore
Gas exhaust pipeTuyau d’échappement gazAuspuffgase MotorTubo de descarga gas
Caricamento carburanteFuel filling
Remplissage carburantTankstutzen
Carga combustible
Entrata ariaAir inletEntrée airLufteintrittEntrada aire
Apertura portelloneCover opening
Overture portillonKlappe öffnenApertura tapa
Apertura pannello frontaleOpening cover front panelOuverture couvercle frontalFrontdeckel öffnenApertura tapa
Uscita aria - Air outletExpulsion air - LuftausttrittSalida aire
Gancio di sollevamento - Central lifting eyeOeillet central de levage - Zentrale HebeöseGancho de elevación
Entrata aria - Air inletEntrée air - LufteintrittEntrada aire
UNPACKING GE_, MS_, TS_M3
© MOSA 1.1-02/04
NOTE!
☞ Be sure that the lifting devices are: correctly mounted,adequate for the weight of the machine with it’spackaging, and conforms to local rules and regula-tions.When receiving the goods make sure that the prod-uct has not suffered damage during the transport,that there has not been rough handling or takingaway of parts contained inside the packing or in theset.In case you find damages, rough handling or ab-sence of parts (envelopes, manuals, etc.), we ad-vise you to inform immediately our Technical Ser-vice.
For eliminating the packing materials, the Usermust keep to the norms in force in his country.
1) Take the machine (C) out of the shipment packing.Take out of the envelope (A) the user’s manual (B).
2) Read: the user’s manual (B), the plates fixed on themachine, the data plate.
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TRANSPORT AND DISPLACEMENTS COVERED UNITS GE_, MS_, TS_M4
© MOSA 1.0-03/00
NOTE!In case you should transport or move the machine, keep to the instructions as per the figures.Make the transportation when the machine has no petrol in its tank, no oil in the engine and and electrolyte in thebattery.Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging, andconform to local rules and regulations.Only authorized persons involved in the transport of the machine should be in the area of movement.
DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION.IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with noCTL accessory).If you did not keep to the instructions, you could damage the structure of the machine.
DANGER: LIFTING EYE IS NOT DESIGNED TO SUPPORTADDED WEIGHT OF ROAD TOW TRAILER
DO NOT LIFT THE MACHINE AND TRAILER
LIFT ONLY THE MACHINE
!
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TRANSPORT AND DISPLACEMENTS COVERED UNITS GE_, MS_, TS_M
4-1© MOSA 1.0-01/01
NOTE!In case you should transport or move the machine, keep to the instructions as per the figures.Make the transportation when the machine has no petrol in its tank, no oil in the engine and and electrolyte in thebattery.Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging, andconform to local rules and regulations.Only authorized persons involved in the transport of the machine should be in the area of movement.
DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION.IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with noCTM accessory).If you did not keep to the instructions, you could damage the structure of the machine.
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Weight max. per person: 35 kgTotal max. weight; 140 kg
ASSEMBLYCTM300CTL300
© MOSA 1.0-09/00
M6.4
Nota: Lift the machine and assemble the parts as shown in the drawing
The CTL or CTM accessory cannot be removed from the machine and used separately (actioned manually orfollowing vehicles) for the transport of loads or anyway for used different from the machine movements.
For assembling the generating set on the trolley CTL300please keep to following instructions:
1) - Lift the generating set (by means of suitable hook).2) - Slightly fix the jaw (3) of the parking foot to the bar
with the M10x20 screws, the M10 nuts and thewashers (so as to let the foot sprag go through.
3) - Split (unscrewing them) the two parts of the foot (4S-4I) to be able later to assemble them on the jaw.
4) - Introduce into the jaw (3) the upper part (4S) of thefoot and screw again the lower part (4I), then tightenthe screws (4V) of the jaw to the towbar and blockmomentaneously with the lever (4L) the whole foot.
5) - Assemble on the machine the towbar (5) complete offoot with the M10x20 screws, nuts and washers (seefig. page M6.4).
6) - Assemble the axle (7) to the base of the machine(see fig. page M6.4) with the M 8x20 screws andrelative washers (two per part) so that their supportscoincide.
7) - Introduce on the axle the antidust ring (7A) withfolded edges turned toward the machine.
8) - Insert the wheel (9) on the axle paying attention tothe spacer (8D) which is between the two bearings,then insert the selfblocking nut (8A) and finally as-semble the shutting cap (8C).
9) - Pump the tyre (9) bringing the pressure to three atms.10)- Lower the machine to the ground and place the
parking foot definitively (regulating at the best height).
ATTENTIONDo not substitute the original tires with other types.
! ATTENTION
34S
4I
4L
4V
!
4
5
7
8D
8A 8C
9
7A
CTM300 CTL300
TRAILERSThe machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a maximum speedof 40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements bynational and foreign traffic norms.
18/0
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M6G
B
Set-up for operation (Engine diesel)TS_GEAir cooled systems
M20
© MOSA 1.1-09/05
16/0
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M20
-R-A
-GB
BATTERY WITHOUT MAINTENANCE
Connect the cable + (positive)to the pole + (positive) of thebattery (after having takenaway the protection), byproperly tightening the clamp.
Check the state of the batteryfrom the colour of the warning light which is in theupper part.
- Green colour: battery OK- Black colour: battery to be recharged- White colour: battery to be replacedDO NOT OPEN THE BATTERY.
RECOMMENDED OILMOSA recommends selecting AGIP engine oil.Refer to the label on the motor for the recommendedproducts.
LUBRICANT
Please refer to the motor operating manual for therecommended viscosity.
It is dangerous to fill the motor with too much oil,as its combustion can provoke a sudden increasein rotation speed.
ATTENTION!
FUEL
Do not smoke or use open flames duringrefuelling operations, in order to avoidexplosions or fire hazards.Fuel fumes are highly toxic; carry outoperations outdoors only, or in a well-ventilated environment.Avoid accidentally spilling fuel. Cleanany eventual leaks before starting upmotor.
ATTENTION!
Refill the tank with good quality diesel fuel, such asautomobile type diesel fuel, for example.
For further details on the type of diesel fuel to use,see the motor operating manual supplied.
Do not fill the tank completely; leave a space ofapprox. 10 mm between the fuel level and the wallof the tank to allow for expansion.
In rigid environmental temperature conditions, usespecial winterized diesel fuels or specific additivesin order to avoid the formation of paraffin.
GROUNDING CONNECTION
The grounding connection to an earthed installationis obligatory for all models equipped with adifferential switch (circuit breaker). In these groupsthe generator star point is generally connected tothe machine’s earthing; by employing the TN or TTdistribution system, the differential switchguarantees protection against indirect contacts.In the case of powering complex installationsrequiring or employing additional electrical protectiondevices, the coordination between the protectiondevices must be verified.For the grounding connection, use the terminal(12); comply to local and/or current regulations inforce for electrical installations and safety.
REFUELLING AND CONTROL:Carry out refuelling and controls with motor at levelposition.1. Remove the oil-fill tap (24)2. Pour oil and replace the tap3. Check the oil level using the dipstick (23); the oil
level must be comprised between the minimumand maximum indicators.
DRY AIR FILTER
Check that the dry air filter is correctly installed andthat there are no leaks around the filter which couldlead to infiltrations of non-filtered air to the inside ofthe motor.
OIL BATH AIR FILTER
Fill the air filter using the same engine oil up to thelevel indicated on the filter.
ENGINE STARTING AND USE (DIESEL ENGINES) GE_, MS_, TS_M21
© MOSA 1.0-06/99
Do not alter the primary conditions of regulationand do not touch the sealed parts.
NOTE!
Check daily
ENGINES WITH MANUAL RECOIL
OFFON
START
ENGINES WITHOUT ACCELERATOR LEVER
lnsert the electric protection device (D-Z2-N2) levertowards above and, where mounted, check theisolation monitor (A3) see page M37 –
Introduce the key (Q1), turn itclockwise completely, leaving it assoon as the engine starts.
NB.: for safety reason the key must be kept byqualified personel.
Let the engine run for some minutes before drawingthe load.
Open the fuel cock (where it is assembled).
OFFON
START
RUNNING-INDuring the first 50 hours of operation, do not usemore than 60% of the maximum output power ofthe unit and check the oil level frequently, in anycase please stick to the rules given in the engineuse manual.
CAUTION!
The machines with E.P.1 engine protection device(D1), use the accelerator lever ONLY INEMERCENCY when the engine protection doesnot work. In this case turn immediately to ourAuthorized Assistance Centers.
NOTE!
ENGINES WITH ACCELERATOR LEVER
Make sure that the accelerator lever or the switch(16) is at its minimum setting.
lnsert the electric protection device (D-Z2-N2) levertowards above and, where mounted, check theisolation monitor (A3) see page M37 –
Introduce the key (Q1), turn itclockwise completely, leaving it assoon as the engine starts and/or thepush button (32) (models without key)leaving it as soon as the engine starts.
☞ NB.: for safety reason the key must be keptby qualified personel.
Once the engine has started leave it running at areduced speed for some minutes.
Accelerate the engine at max., set lever on maximumposition and then take up load.
Hold the starting handle firmly.
Pull the rope hard and fast. Pull itall the way out. Use two hands ifnecessary.
Then returning it slowly.
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M20
-GB
ENGINE STARTING AND USE (DIESEL ENGINES) GE_, MS_, TS_M
21.1© MOSA 1.0-06/99
ENGINE WITH PREHEATING GLOWPLUGS
Turn the starter key (Q1) on the position „preheatingglow plugs“ (the glow plugs light will be on I4), whenthe light is off, turn the starter key completelyclockwise until the engine begins to fire.Let the engine run for some minutes before drawingthe lood.
ENGINES WITH R.P.M. ELECTRONICADJUSTER (ONLY FOR GENERATING SET)
Turn the starter key (Q1) completely clockwiseuntil the engine begins to fire.
☞ Wait for the AUTOMATIC preheating time beforedrawing the load
OCCASIONAL USE OF THE ENGINEUsing the engine in special conditions which needan immediate intervention, such as emergencyplants, etc., use advise to use our EngineAssistance Centres for specific interventions orour Technical Assistance Service.
If the engine fails to start, do not insist for at least15 seconds.Space the further operations waiting for at least4 minutes.
CAUTION!
RUNNING-INDuring the first 50 hours of operation, do not usemore than 60% of the maximum output power ofthe unit and check the oil level frequently, pleasefollow the instructions on the engine use andmaintenance manual..
CAUTION!MACHINE WITH EMERGENCY BUTTON
Before starting the engine, make sure that theemergency button (32B) is off (turn the buttonclockwise for this operation)
CAUTION!
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M20
-GB
STOPPING THE ENGINE (DIESEL ENGINE) GE_, MS_, TS_M22
© MOSA 1.0-10/00
☞ Before stopping the engine it is compulsory toeffect the following operations:
- stop to draw three/single-phase current from theauxiliary sockets.
- stop to draw power from the welding sockets(only for TS models).
ENGINES WITH ACCELERATOR LEVER
☞ Make sure that the unit ls not supplying anypower.
Disconnect the electrical protection device (D-Z2-N2) lever downward.
Set the accelerator lever or the switch (16) tominimum position and wait for a few minutes toallow the engine to cool, anyway follow theinstructions contained in the engine manual.
Pull the stop lever (28) until the engine stops (whereit is assembled).
Remove the key (Q1) turning it counterclockwise, OFF position, then take itout.
☞ NB.:for safety reason the key must be keptby qualified personel.
ENGINES WITHOUT ACCELERATOR LEVER
Make sure that the unit is not supplying any power.
Disconnect the electrical protection device (D-Z2-N2) lever downward.Let the engine idle for a few minutes.
Press the pushbutton (F3) until the engine stops
OFFON
START
(where it is assembled).
Shut the fuel cock (where it is assembled).
Remove the key (Q1) turning it counterclockwise, OFF position, then take itout.
☞NB.: for safety reason the key must be keptby qualified personel.
ENGINES WITH R.P.M. ELECTRONICADJUSTER (ONLY FOR GENERATING SET)
Make sure that the unit is not supplying any power..Disconnect the electrical protection device (D-Z2-N2 lever downward.
Let the engine idle for a few minutes.
Press the pushbutton (F3) until the engine stops(where it is assembled).
Remove the key (Q1) turning it counterclockwise, OFF position, then take itout.
☞ NB.: for safety reason the key must be keptby qualified personel.
OFFON
START
OFFON
START
MACHINE WITH EMERGENCY BUTTONPressing it, it allows to stop the engine in anycondition (32B) (when assembled).To re-establish it, see page M21...
CAUTION!
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M20
-GB
CONTROLS LEGENDE GE_, MS_, TS_M30
© MOSA 1.0-05/01
4A Hydraulic oil level light9 Welding socket ( + )10 Welding socket ( - )12 Earth terminal15 A.C. socket16 Accelerator lever17 Feed pump19 48V D.C. socket22 Engine air filter23 Oil level dipstick24 Engine oil reservoir cap24A Hydraulic oil reservoir cap24B Water filling cap25 Fuel prefilter26 Fuel tank cap27 Muffler28 Stop control29 Engine protection cover30 Engine cooling/alternator fan belt31 Oil drain tap31A Hydraulic oil drain tap31B Water drain tap31C Exhaust tap for tank fuel32 Button33 Start button34 Booster socket 12V34A Booster socket 24V35 Battery charge fuse36 Space for remote control37 Remote control42 Space for E.A.S.42A Space for PAC47 Fuel pump49 Electric start socket54 Reset button PTO HI55 Quick coupling m. PTO HI55A Quick coupling f. PTO HI56 Hydraulic oil filter59 Battery charger thermal switch59A Engine thermal switch59B Aux current thermal switch59C Supply thermal switch wire feeder-42V59D Pre-heater (spark plug) thermal switch59E Supply thermal switch oil/water heather63 No load voltage control66 Choke control67A Auxiliary / welding current control68 Cellulosic electrodes control69A Voltmeter relay70 Warning lights71 Selecting knob72 Load commut. push button73 Starting push button74 Operating mode selector75 Power on’ warning light76 Display79 Wire connection unit86 Selector86A Setting confirmation87 Fuel valve88 Oil syringeA3 Insulation monitoringA4 Button indicating light 30 l/1' PTO HIB2 Engine control unit EP2B3 E.A.S. connectorB4 Exclusion indicating light PTO HI
B5 Auxiliary current push buttonC2 Fuel level lightC3 E.A.S. PCBC6 Control unit for generating sets QEAD Ground fault interrupter ( 30 mA )D1 Engine control unit and economiser EP1D2 AmmeterE2 Frequency meterF FuseF3 Stop switchF5 Warning light, high temperatureF6 Arc-Force selectorG1 Fuel level transmitterH2 Voltage commutatorH6 Fuel electro pumpI2 48V A.C. socketI3 Welding scale switchI4 Preheating indicatorI5 Y/▲ switchI6 Start Local/Remote selectorL A.C. output indicatorL5 Emergency buttonL6 Choke buttonM Hour counterM1 Warning level lightM2 ContactorM5 Engine control unit EP5M6 CC/CV switchN VoltmeterN1 Battery charge warning lightN2 Thermal-magnetic circuit breaker/Ground fault
interrupterN5 Pre-heat push-buttonN6 Connector - wire feaderO1 Oil pressure warning light/Oil alertP Welding arc regulatorQ1 Starter keyQ3 Derivation boxQ4 Battery charge socketsR3 SirenS Welding ammeterS1 BatteryS3 Engine control unit EP4S6 Wire feeder supply switchS7 Plug 230V singlephaseT Welding current regulatorT4 Dirty air filter warning light/indicatorT5 Earth leakage relayT7 Analogic instrument V/HzU Current trasformerU3 R.P.M. adjusterU4 Polarity inverter remote controlU5 Relase coilV Welding voltage voltmeterV4 Polarity inverter controlV5 Oil pressure indicatorW1 Remote control switchW3 Selection push button 30 l/1' PTO HIW5 Battery voltmeterX1 Remote control socketY3 Button indicating light 20 l/1' PTO HIY5 Commutator/switch, serial/parallelZ2 Thermal-magnetic circuit breakerZ3 Selection push button 20 l/1' PTO HIZ5 Water temperature indicator
10/0
5/01
M30
-GB
ComandiControlsCommandes© MOSA 1.1-12/05
14/0
3/02
219
82
E
D
NL
BedienelementeMandos TS 300 SC/SXC
M31
Front panel components GE_, MS_, TS_M32
© MOSA 1.0-11/99
According to the version of the machine on the frontpanel there are assembled some instruments:
warning lights (L) corresponding to the currentsockets on the front panel, indicate that thecurrent can be drawn from the sockets whenthey are lit (15);
voltmeter (N);
GFI (D), Thermal magnetic circuit breaker (Z2)(TS...PL: : one for each auxiliary socket) orThermal magnetic circuit breaker/GFI (N2);
voltage selector switch (H2);
insulation monitoring (A3)-See page M 39.10 -;
hour-counter (M), which indicates the hours ofeffective operation of the unit;
fuse (F), which protects the electric circuit of theengine, replacement of which, in case it breaks,must be effected absolutely with the machinestopped. Remove the mechanical protection,then shift down the small lever of the fuse holderplaced on the front panel;
fuel level gauge (M1): when the quantity of fuelin the tank falls below 5 Iitres a worning light onthe instrument panel lights up;
fuel level indicator (C2);
preheating glow plugs warning light (I4) for thepreheating (for diesel engines it shows theintervention time of the glow plugs);
dirty air filter warning light (T4);
ammeter (D2) indicates the drown current. Incase current is drawn simultaneously fromseveral sockets, it shows the current sum. (DONOT GO OVER THE MAX. CURRENTINDICATED ON THE LABEL);
star/ triangle switch (I5);
frequency meter (E2), that indicates thefrequency generated and therefore the numberof revolutions of the engine: the frequencyshould be of 52 Hz» or 62 Hz» when the unit isidle and about 50 Hz or 60 Hz at full load (incose that the found volue is different make surethat the engine is completely accelerated), (donever use the unit with a frequency lower than49 Hz or 59 Hz, in this case decrease the load);
tone horn (R3) ) indicates the defects in theengine;
10
20
30
MTD
4/4
½0
A
engine protections: EV - EP1 (D1) (for engine at3000/3600 rpm.), EP2 (B2 for engine at 1500/1800 rpm), EP4 – EP5 (M5)- See pag. M39 .... -;
starter key (Q1) and engine stop;
welding socket (gouging, when assembled, -9+ - 10- ) - See pag. M 34 -;
Emergency button (L5);
Control switch for accelerator (only for engineat 3000/3600 rpm) -
☞ WE ADVISE TO USE THE SWITCH ONLY IFTHE EP1 DEVICE IS BROKEN);
auxiliary current push button (B5);
welding current regulator (T) and/or „arc force“selector (F6) - See pag. M34 -1;
welding scale switch (I3);
polarity inverter control (V4);-See pag M34 -1;
cellulosic electrodes control (68);-See pag M34 -1;
Protection fuse for welding PCB, weldingammeter (S);
remote control switch (W1) and remote controlsocket (X1) - See pag M38 .... -;
switch CC/CV (M6)-See pag M34 -1;-
OFFON
START
ONLY GOUGING
ON
OFF
ARC FORCE
100%
XXX A
max
Polarity
switch
ON
OFF
ON
OFF
CC
CV09
/11/
99 M
32-G
B
USE AS WELDER TSM34
© MOSA 1.0-04/04
This symbol (Norm EN 60974-1 securitystandards for arc welders ) signifies thatthe welder can be used in areas withincreased risk of electrical shock.
The sockets, after the machine is started (seepages M21-26), also with no cables, are anywayunder voltage.
ATTENTION!
The areas, access of which is forbiden tounqualified personel, are:- the control switchboard (front) - the exhaust ofthe endothermic engine - the welding process.
ATTENTION!
To reduce the r isk of electromagneticinterferences, use the minimum lenght of weldingcables and keep them near and down (ex. on thefloor).The welding operations must take place far fromany sensitive electronic device.Make sure thatthe unit is earthed. (see M20 and/or M25). Incase the interference should last, adapt furtherdisposition,such as: move the unit, use screenedcables, line filters, screen the entire work area.In case the above mentioned operations are nonsufficient, please contact our ThechnicalAssistance Service.
ATTENTION!
Check at the beginning of any work the electricparameters and/or the control placed on the front.
Make sure that the ground connection (12) is efficent(keep to installation local rules and/or to nationallaws), in order to integrate or ensure the working ofvarius electric protection devices referring to theseveral distribution system TT/TN/IT, operationunnecessary for machine with isometer.
Fully insert the welding cable plugs into thecorresponding sockets (“only gauging”, 9+/10-)turnning them clockwise to lock them in position.
MACHINES WITH E.V. PROTECTIONAccelerate the engine at max. with the acceleratorlever (16).See page M 39.
MACHINE WITH E.P.2 PROTECTION (B2)Accelerate the engine at max. with the acceleratorlever (16) (when assebled).See page M 39
MACHINE WITH E.P.1 PROTECTION (D1)See page M 39.1
REMOTE CONTROL TC…See page M 38
WELDING CURRENT REGULATORPosition welding current adjustingknob (T) in correspondance of thechasen current value, so as toobtain the necessary amperage,taking into acount the diameter andthe type of the electrode.For technical data see page M52
With a welding cable length up to 20 m issuggested a section of 35 mm²; wìth longercables a bigger section is required.
CAUTION!
ONLY GOUGING
☞ Make sure that the ground clamp ,whose cablemust be connected to the + or - terminal,depending on the type of electrode, makes agood connection and is near to the weldingposition.Pay attention to the two polarities of the weldingcircuit, which must not come in electric contactbetween themselves.When using the welder for air arc gougingconnect the ground lead to the - socket andthe gouging lead to the socket marked "onlygouging" (if present).
PUSH ANDTWIST
06/0
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M34
-GB
USE AS WELDER TSM
34.1© MOSA 1.0-04/04
MACHINE WITH REDUCTION SCALESWITCH
For small electrodes (up to Ø 3.25-130Aand 4-200A) it is recommended to use thereduction scale switch (I3) allowing a moreaccurate regulation of the welding current(lever position at 130 A and/or 200A).
When using electrodes of a diameter greater than3.25 and/or 4 set the welding scale knob to 100%and/or max. position.The arc regulator (T) functions equally betweenboth positions (100%-130A and/or 200A).
Protection fuse (when assembled):the fuseprotects the electronic welding PCB in casethe remote control is short circuited.
MACHINE WITH O.C.V.
lt permits to choose, according to the work to bedone and/or the electrode type used,the best O.C.V.
MACHINE WITH POLARITY INVERTER
lt permits to have at the electrodeholder the positive or negativepolarity of the welding diode bridge.It is used above all in the first run
with cellulosic electrodes to lower the bathtemperature and so doing ease up the welding onpipes of small thickness
MACHINE WITH BASIC CURRENT "BC"
Positioning the switch on „ON“, is obtained a lowvoltage welding current which keeps,always, the lit arc necessary for sometypes of cellulosic electrodes or when ahigh penetration is wanted.
For electrodes of basic or rutile type,position the switch on "OFF", the welding currentwill always remain constant.
"CC/CV" MODELS
These models can be used withelectrodes or for TIG welding byselecting the CC (constant current)mode, and with solid wire (MIG, MAG)or flux cored wire selecting the CV(constant voltage) mode. The mode ofoperation is selected by a switch on thefront panel.
MACHINE WITH ARC CONTROLOR SELECTOR "ARC FORCE"
Set the welding arc usingadjuster knob (6) so as to abtain,for the chosen current value,the best arc characteristicaccording to the electrode typeand to the work to be performed.
Polarity
switch
65V
75V
ON
OFF
CC
CV
ARC CONTROL
CONTROLLO ARCO
1
2
3
65
4
9
8
7
ON
OFF
ARC FORCE
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M34
-GB
100%
XXX A
max
On machines with an Arc Forceselector, the same result can beobtained by turning the selector "ON"or "OFF". When switched "ON" a basecurrent is applied to the welding currentoutput acting as a sort of "automatic"arc forcing that does not need to beregulated.
For technical data see page M52
☞ At the end of every welding process and/orwork, proceed with all the use operations ininverted sense.
To stop the machine see pages M 22-27.
USE AS A GENERATOR GE_, MS_, TS_M37
© MOSA 1.0-06/99
Sockets are not self-locked: tension is avaibleimmediately after starting also with no plug.
WARNING!
☞ �
It is strictly forbidden to connect the groupto the public mains a/o to another source ofelectric power.
The replacement of the fuse must absolutely bedone with the engine off (remove the mechanicalprotection, then shift down the small lever of thefuse holder placed on the front panel).
CAUTION☞ At the beginning of every work, check the
electric parameters and/or the controls placedon the front.
Make sure the unit is properly grounded (12) (whereit is assembled).- See page M20, 21, 22, 25, 26, 27 -.
Move the accelerator lever (16) and reach the enginemaximum speed, except for the engines withconstant rpm; the voltmeter (N) (where it isassembled) shows the single-phase voltage whetherthree or single-phase current has to be drawn.
*N.B.: with electronic tens. regul. RVT ±1%
Connect up the machine, using proper plugs andcables in good condition to the AC socket (15) todraw single or three-phase power, or, by cableswith adeguate section, to the terminal board, placedinside the derivation box (Q3).
Nominalvoltage
110V230V230V400V
asynchronous±10%±10%±10%±10%
synchronous (*)±5%±5%±5%±5%
Indicative no-load voltage
The areas, access of which is forbidden tounqualified personel, are:- the control switchboard (front), the exhaust ofthe endothermic engine.
WARNING!
The warning light (L), located near the currentsocket, lights up when the unit can supply alternatedcurrent, on condition that the engine is at themaximum rpm.
☞ N.B.: if the warning light does not flash, checkthe accelerator which must bebat itsmaximum, or the fuse of the relevantsocket. (single-phase) or thethermoprotection.
Using several sockets at tha same time, themaximum power possible is that indicated on thedata plate.
To draw power simultaneously in the TS welderversion see page M52.
!
The max. continuous power of the generating set ortheload current must not be exceeded.
MACHINE WITH THERMOPROTECTION
If you overload the genset the thermoprotection willautomatically switch off.lf the thermoprotection is released, disconnect allthe connected loads.
Reset the thermoprotection pressing the centralpole.When reset, connect the loads again.In case the protection should act furtherly, check:the connections, the wires or others, and ifnecessary call the Assistance Service.
AvoId to hold the centralpole of thet h e r m o p r o t e c t i o npressed for a long time.
Otherwise, in case of trouble, it will not click,damaging the generating set.
CLOSED OPEN
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M37
-GB
PRESS TORESET
USE AS A GENERATOR GE_, MS_, TS_M
37.1© MOSA 1.0-06/99
TS ... PL VERSIONStart the machine and wait for the end of thepreheating time imposed by the EP1, EP2, EP5engine protection device. - See pages M39... -Press the „generation possibility“ push button (B5)placed on the font side of machine.The voltmeter will show the auxiliary voltage which,for machines at 1500/1800 RPM, must. be approx.�230V ± 10% and for machines at 3000/3600 RPM(engine idling) must. be approx. �180V ± 10%.
Push upwards the lever of magnetothermic switchreffering to the socket from which load is to bedrawn.
MACHINE WITHOUT PROTECTIVE DEVICEIn case machine is not equipped wìth protectivedevice of indirect contacts, by means of automaticbreaking of supply, it is necessary to put betweenthe load and the generatíon a differential swítch or asimilar equipment capable, in any case, to observethe regulations in force CEI 64/8 (and/or successi-ve) Part 4 Par. 4.13.1 and harmonzed by directiveNr. 72/23/EEC.
UNIT FITTED WITH GROUND FAULTINTERRUPTER SWITCH (GFI)
Turn on the GFI safety-switch(D) by pushing it upwards.
The GFI is a safety device which protects thecircuit in the event of a malfunction. In this case theswitch disconnects the three and single-phasecircuit when in any part of the electric connectionsa current leakage of more than 30 mA occurs.
UNIT FITTED WITH THERMAL MAGNETICBREAKER
Turn on the thermal magneticbreaker (Z2) by pushing it tothe ON position.
The thermal-magnetic breakeris a safety device which
protects the circuìt in the event of a malfunction. Inthis case the switch disconnects the three andsingle-phase circuit when in any part of the electricconnections a short circuit or a current absorptionoccurs above the data specified on the label of theunit.In the model with setting DO NOT INTERVENE onthe setting itself. To modify it, please contact ourTechnical Assistance Service.
UNIT FITTED WITH GFI SWITCH THERMALMAGNETIC BREAKER
For machines at 3000/3600 RPM the EP1 safetydevice will automatically provide to accelerateengine when load is drawn.- See page M39.1 -
CAUTION!
This switch includes the characteristics of bothtypes of breakers (N2).
UNIT WITH VOLTMETRIC COMMUTATOR (ONLYFOR GENERATING SET)
☞ WARNING: the possiblesingle-phase loads mustbe correctly divided in thethree phases, in order toavoid any possible voltagefall on one phase thatresults excessivelyloaded.
Check the voltages on the various phases with theswitch located on the front (H2) and check, readingon the voltmeter (N) about the same voltage value
☞ N.B.: in case of overload, it is possible that theengine lowers its speed and the voltageis reduced remarkably. In this case, it isnecessary to reduce immediately theload.
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-GB
ACCESSORY USE REMOTE CONTROLTC2 / TC2/50
M38
© MOSA 1.1-06/05
The remote control device for regulating the weldingcurrent is connected to the front panel by means ofa multipole connector.
To regulate the current from the TC2 / TC2/50,move the switch (7), located above the multipoleconnector (8), to "ON" position.
Position welding current adjusting (T) knob at thenecessary current value for the diameter and typeof electrode.- See page M51 -
ON
OFF
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M38
GB
PUSH ANDSCREW TIGHT
ACCESSORY USEPAR 600
M38.3
GB© MOSA 1.0-04/04
1) the both positions have an identic polarity2) that O.C.V. have an identic position - See page M34.2 -
MAKE SURE!
The device enables to totalize the welding currentof two positions or of two welding machine.
Connect each one of the inputs "+" and "-" of thePAR 600 to each welding position and draw,according to the use, the total current from the "+"and "-" output socket.
Fully insert the welding cable plugs into thecorresponding socket (9+/10-) turning themclockwise to lock them in posotion. PUSH AND TWIST
06/0
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M38
-3G
B
USE AND MAINTENANCE ENGINE PROTECTION EP1M
39.1© MOSA 1.1-10/05
IN THE FIRST FRACTION OF TIME THE DEVICE DOESNOT MAKE ANY PROTECTION.
CAUTION!
ENGINE PROTECTION (EP1)
The electronic device EP.1 (D1) is a microprocessorwith logic-circuit board that ensures the protectionof the engine in case of low oil pressure or enginehigh temperature.
Located on the front of the machine, the EP.1 entersin operation when the engine has been turned onwith the ignition key.
The yellow warning light for low oil temperature(D1.1) will immediately light up; after 15 secondsthe emgine will be checked and if everything isoperating normally, the "OK engine" light will switchon.11515
The automatic device requires an engine warningup time of at least 45 seconds, not permitting todraw power when the engine is still cold.
☞ N.B.: A longer warning up time (4-5 minutes) isadvisable for temperatures below +10°C.
When the warning light (D1.1) goes off, whether theunit is used as welder or as a generator, the greenlight (D1.5) will light up, hte engine will go to maximumspeed ,permitting to draw power.Should the oil pressure be insufficent, the red light(D1.3) will light up and the EP.1 device will stop theengine.If the temperature rises to dangerous levels, thered light (D1.4) will light up and the engine will stopthus preventing to draw power.
LIQUID COOLED ENGINEIn case of cooling liquid high temperature, thewarning light (D1.4) will light up and the engine willstop thus preventing to draw power.In this case it is SUGGESTED to stop the engineand control the cooling level.
In case of low pressure, check the level and if it iscorrect, call the service station. In case of hightemperature, make sure that there are no leavesand/or pieces of material obstructing tha air circuit.
COLORSG = yellowV = greenR = red
THE ENGINE PROTECTIONS OF THE “EP” TYPEDO NOT WORK WHEN THE OIL IS OF LOW QUALITYBECASE NOT CHENGED REGULARY AT INTERVALSAS PRESCRIBED IN THE OWNER’S ENGINEMANUAL.
NOTE!
N.B.: if the unit is used as a generator in hotclimates and with loads near to the maximum, theprotection can be triggered off, please reduce theload of the engine.
Once the cause of the problem has been removed,to ensure the protection it is sufficent to set the keyto zero and restart the engine.
ENGINE EQUIPPED WITH A MANUALACCELERATOR
NOTE: This unit is equipped with a manualaccelerator for use in the unlikely event that the EP.1or the accelerator solenoid should fail.This manualaccelerator can also be used in cases where theauto-idle function is not suitable for the type of weldingbeing carried out.
CAUTION: for machines withEP.1 engine protection: use theaccelerator lever ONLY INEMERGENCY when theautomatic idle does not work.
Accelerator lever
MIN
MAX
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-GB
D1.1(G) Low oil temperature/Cold engine
D1.2(V) Engine test/ OK engine
D1.3(R) Low oil pressure
D1.4(R) High temperature
D1.5(V) Engine at maximum
USE OF THE PROTECTION ENGINE PROTECTIONES - EV
M39.4
© MOSA 1.1-04/03
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High temperature
Low oil pressure
ENGINE PROTECTION (ES - EV)
The devices ES or EV ensure the protection of theengine in case of low oil pressure or engine hightemperature.
The system consist of electronic card of controland check, and of an engine stop device: solenoid(ElettroStop), electrovalve (ElettroValvola)
The device enter in operation when the enginestarts and, in case of low oil pressure and hightemperature, will stop the machine and show thecause of the stop with the warning light of hightemperature or low oil pressure.
In case of low oil pressure, check the level and if itis correct, call the Service Station. In case of hightemperature, make sure that there are no leavesand/or pieces of material obstructing the air ducts.
☞ N.B.: if the unit is used as a generator in hotclimates and with loads near to the maximum,the protection device can be triggered off, pleasereduce the load of the engine.
Once the cause of the problem is removed, to resetthe protection, it is enough to report the ignition key(Q1) on "OFF" position and start the engine again.
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TROUBLE SHOOTING TSM
40.1© MOSA 1.0-04/04
PROBLEMNo welding current butauxiliary output is OK
Weld poorly
Intermittently welds poorly
No welding output andno auxiliary poweroutput
POSSIBLE CAUSE1) Defective diode bridge2) Problem with welding current control
(PCB)
1) Defective diode bridge
2) Problem with welding current control(PCB)
1) Bad connections to welding current PCB
2) Problem with welding current controlPCB
1) Short circuit in wiring
2) Defective condenser
3) Defective stator
4) Short circuited diode bridge
WHAT TO DO1) Check the diodes of the bridge2) Is the remote control switch in the
internal position?3) Check the diodes and SCR’s of the
bridge.4) Check the transformer which supplies
power to the welding control PCB. If itis OK replace the PCB
1) Check the open circuit weldingvoltage.
If it is OK the diode bridge is OK. If itis 1/3 or 2/3 of the nominal valuecheck the diodes or the SCR’s.
2) If the diode bridge is OK replace thePCB.
1) Check that the pins of the greenconnectors are clean and makinggood contact.
Check that shunt connections are tight.
2) Replace the welding current controlPCB
1) Check the wiring inside the welder fora short circuit between cables or toground.
2) If the wiring is OK, short circuit thecondenser to be sure that it isdischarged, disconnect all wires fromcondenser and, using an ohmmeter,check that the condenser is not shortcircuited.
3) If the condenser box is OK,disconnect all leads from the statorexcept for those going to thecondenser box and check theoutput from the alternator.
If there is no output from the weldingwinding and the auxiliary winding,replace the stator.
4) If there is output from all windingsreconnect the diode bridge and checkif there is welding current. If not thediode bridge is defective. If there iswelding current connect the auxiliarypower leads one at a time until thereis no output; at this point, the shortcircuit is in that line.
only for models with electronic control of welding current.○ ○ ○
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-1-I
MAINTENANCEM43
© MOSA 1.0-09/05
NOTE
By maintenance at care of the utilizer we intend all theoperatios concerning the verification of mechanical parts,electrical parts and of the fluids subject to use orconsumption during the normal operation of the machine.
For what concerns the fluids we must consider asmaintenance even the periodical change and or the refillseventually necessary.
Maintenance operations also include machine cleaningoperations when carried out on a periodic basis outsideof the normal work cycle.
The repairs cannot be considered among themaintenance activities, i.e. the replacement of partssubject to occasional damages and the replacement ofelectric and mechanic components consumed in normaluse, by the Assistance Authorized Center as well as byMOSA.
The replacement of tires (for machines equipped withtrolleys) must be considered as repair since it is notdelivered as standard equipment any lifting system.
The periodic maintenance should be performed accordingto the schedule shown in the engine manual. An optionalhour counter (M) is available to simplify the determinationof the working hours.
THE ENGINE PROTECTION NOT WORK WHEN THEOIL IS OF LOW QUALITY BECAUSE NOT CHARGEDREGULARLY AT INTERVALS AS PRESCRIBED INTHE OWNER’S ENGINE MANUAL.
NOTE!
IMPORTANTIn the maintenance operations avoid thatpolluting substances, liquids, exhausted oils,etc. bring damage to people or things or cancause negative effects to surroindings, healthor safety respecting completely the laws and/or dispositions in force in the place.
!
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, payattention moving parts, hot parts (exhaust manifold and muffler,etc.) electrical parts which may be unprotected when the machineis open.
● Remove guards only when necessary to perform maintenance, andreplace them when the maintenance requiring their removal iscomplete.
● Use suitable tools and clothes.● Do not modify the components if not authorized.
- See pag. M1.1 -
HOT surfacecan
hurt you
MOVINGPARTS
can injure
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ENGINE and ALTERNATORPLEASE REFER TO THE SPECIFIC MANUALSPROVIDED.
VENTILATIONMake certain there are no obstructions (rags, leaves orother) in the air inlet and outlet openings on the machine,alternator and motor.
ELECTRICAL PANELSCheck condition of cables and connections daily.Clean periodically using a vacuum cleaner, DO NOTUSE COMPRESSED AIR.
DECALS AND LABELSAll warning and decals should be checked once a yearand replaced if missing or unreadable.
STRENUOUS OPERATING CONDITIONSUnder extreme operating conditions (frequent stops andstarts, dusty environment, cold weather,extended periodsof no load operation, fuel with over 0.5% sulphur content)do maintenance more frequently.
BATTERY WITHOUT MAINTENANCEDO NOT OPEN THE BATTERY
The battery is charged automatically from the batterycharger circuit suppplied with the engine.
Check the state of the battery from the colour of thewarning light which is in the upper part.
- Green colour: battery OK- Black colour: battery to be recharged- White colour: battery to be replaced
STORAGE GE_, MS_, TS_M45
© MOSA 1.0-06/00
In case the machine should not be used for more than 30days, make sure that the room in which it is storedpresents a suitable shelter from heat sources, weatherchanges or anything which can cause rust, corrosion ordamages to the machine.
☞ Have qualified personnel prepare the machine forstorage.
GASOLINE ENGINE
Start the engine: lt will run until it stops due to the lack offuel.
Drain the oil from the engine sump and fill it with new oil(see page M25).
Pour about 10 cc of oil into the spark plug hole and screwthe spark plug, after having rotated the crankshaft severaltimes.
Rotate the crankshaft slowly until you feel a certaincompression, then leave it.
In case the battery, for the electric start, is assembled,disconnect it.
Clean the covers and all the other parts of the machinecarefully.
Protect the machine with a plastic hood and store it in odry place.
DIESEL ENGINE
For short periods of time it is advisable, about every 10days, to make the machine work with load for 15-30minutes, for a correct distribution of the lubricant, torecharge the battery and to prevent any possible blokingof the injection system.
For long periods of inactivity, turn to the after solesservice of the engine manufacturer.
Clean the covers and all the other parts of the machinecarefully.
Protect the machine with a plastic hood and store it in adry place.
In the storage operations avoid thatpolluting substances, liquids, exhaustedoils, etc. bring damage to people orthings or can cause negative effects tosurroindings, health or safety respectingcompletely the laws and/or dispositionsin force in the place.
! IMPORTANT
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In case of necessity for first aid and of fire prevention,see page. M2.5.
CUST OFF GE_, MS_, TS_M46
© MOSA 1.0-03/00
In the cust-off operations avoid thatpolluting substances, liquids, exhaustedoils, etc. bring damage to people orthings or can cause negative effects tosurroindings, health or safety respectingcompletely the laws and/or dispositionsin force in the place.
! IMPORTANT
☞ Have qualified personnel disassemble themachine and dispose of the parts, including theoil, fuel, etc., in a correct manner when it is tobe taken out of service.
As cust off we intend all operations to be made,atutilizer’s care,at the end of the use of the machine.This comprises the dismantling of the machine, thesubdivision of the several components for a furtherreutilization or for getting rid of them, the eventualpacking and transportation of the eliminated partsup to their delivery to the store, or to the bureauencharged to the cust off or to the storage office,etc.
The several operations concerning the cust off,involve the manipulation of fluids potentiallydangerous such as: lubricating oil and batteryelectrolyte.
The dismantling of metallic parts liable to causeinjuries or wounds, must be made wearing heavygloves and using suitable tools.
The getting rid of the various components of themachine must be made accordingly to rules in forceof law a/o local rules.Particular attention must be paid when gettingrid of:lubricating oils, battery electrolyte, andinflamable liquids such as fuel, cooling liquid.
The machine user is responsible for the observanceof the norms concerning the environment conditionswith regard to the elimination of the machine beingcust off and of all its components.
In case the machine should be cust off without anyprevious disassembly it is however compulsory toremove:- tank fuel- engine lubricating oil- cooling liquid from the engine- battery
NOTE: MOSA is involved with custing off themachine only for the second hand ones, when notreparable.This, of course, after authorization.
In case of necessity for first aid and fire prevention,see page M2.5.
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ry²rx²
7²4²
The TS 200 BS/CF engine driven welder ia a unit which ensures the function as:a) a current source for arc weldingb) a current source for the auxiliary power generationIt is meant for industrial and professional use, powered by an endothermic engine; it is composed ofvarious main parts such as: engine, alternator, electric and electronic controls, the fairing or a protective structure.The assembling is made on a steel structure, on which are provided elastic support which must damp the vibrations and alsoeliminate sounds which would produce noise.
OUTPUTDeclared powers at the following ambient conditions: temperature 20*C, relative humidity 30% altitude 100 m above sea level.In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.For possible modifications or changes to be brought on the engines, with climate conditions different from those abovementioned, please call our Assistance Authorized Centers.
ACOUSTIC POWER LEVELThe machine respects the noise limits, expressed in sound power, given in the a.m. directives.These limits can be used to judge the sound level produced on site.For example: the sound power level of 100 LWA.The sound pressure (noise produced) at 7 meters distance is about 75dBA (the limit value less 25).To calculate the sound level at other distances use this formula:
dBAx = dBAy + 10 log At 4 meters the noise level becomes: 75 dBA + 10 log = 80 dBA
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Technical data TS 300 SC - SXCM51
© MOSA 1.1-12/05
Technical data TS 300 SC TS 300 SXCALTERNATOR self-excited, self-regulated, brushless
Type Three-phase, asynchronousInsulating class H
A.C. GENERATORA.Three-phase generation 10 kVA / 400 V / 14.4 ASingle-phase generation 5 kVA / 230 V / 21.7 ASingle-phase generation 2.5 kVA / 110 V / 22.7 4Single-phase generation 5 kVA / 48 V / 104 AFrequency 50 HzService 100 %
ENGINEMark RUGGERINIModel RD 210
Type 4-StrokeDisplacement 954 cm3
Cylinders 2Output 14 kW (19 HP)Speed 3000 rpmFuel consumption 250 g/kWhCooling system AirEngine oil capacity 3 lStarter ElectricFuel Gasoline
GENERAL SPECIFICATIONSBattery 12V - 45AhTank capacity 23 lRunning time (60%) 9 hProtection IP 23Dimensions / max. (Lxlxh in mm) 1320x790x750Dimensions with CTM 1630x920x930Dimensions with CTL 2050x980x990Weight 350 Kg 370 KgWeight with CTM 370 Kg 390 KgWeight with CTL 410 Kg 440 KgNoise Level 99 LWA (74 dB(A) - 7m) 93 LWA (68 dB(A) - 7m)
Technical data TS 300 SC TS 300 SXCD.C. WELDING C.C.
Welding current regulation (I Scale) 20 - 300 AService 300 A - 60%, 250 A - 100%Regulation of welding * 0 - 9Open circuit voltage 70 VWelding voltage 20 - 32 VØ electrode 2 - 6 mm
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Technical data TS 300 SC - SXCM52
© MOSA 1.1-12/05
SIMULTANEOUS UTILIZATION FACTORS
In case Welding and Generation can be used simultaneously, however, the engine cannot be overloaded. The ta-ble below gives the maximum limits to be respected:
OUTPUT CARACTERISTIC
0 - 9*
3002401508020
10050250Welding current regulator position
approx. current values
75%
A
AUXILIARY POWER
WELDING CURRENT
10 kVA5 kVA2.5 kVA0
80 A130 A>170 A 0 A
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DimensioniDimensionsDimensions© MOSA 1.1-12/05
AbmessungenDimensiones TS 250-300 SC/SXC
M53E
D
NL