Mosa TS 400 PS-BC Use And Maintenance Manual Download

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ELECTRICAL SYSTEM LEGENDE

REV.10-05/13

26/07/04 M60GB

A : Alternator

B : Wire connection unit

C : Capacitor

D : G.F.I.

E : Welding PCB transformer

F : Fuse

G : 400V 3-phase socket

H : 230V 1phase socket

I : 110V 1-phase socket

L : Socket warning light

M : Hour-counter

N : Voltmeter

P : Welding arc regulator

Q : 230V 3-phase socket

R : Welding control PCB

S : Welding current ammeter

T : Welding current regulator

U : Current transformer

V : Welding voltage voltmeter

Z : Welding sockets

X : Shunt

W : D.C. inductor

Y : Welding diode bridge

A1 : Arc striking resistor

B1 : Arc striking circuit

C1 : 110V D.C./48V D.C. diode bridge

D1 : E.P.1 engine protection

E1 : Engine stop solenoid

F1 : Acceleration solenoid

G1 : Fuel level transmitter

H1 : Oil or water thermostat

I1 : 48V D.C. socket

L1 : Oil pressure switch

M1 : Fuel warning light

N1 : Battery charge warning light

O1 : Oil pressure warning light

P1 : Fuse

Q1 : Starter key

R1 : Starter motor

S1 : Battery

T1 : Battery charge alternator

U1 : Battery charge voltage regulator

V1 : Solenoid valve control PCBT

Z1 : Solenoid valve

W1 : Remote control switch

X1 : Remote control and/or wire feeder

socket

Y1 : Remote control plug

A2 : Remote control welding regulator

B2 : E.P.2 engine protection

C2 : Fuel level gauge

D2 : Ammeter

E2 : Frequency meter

F2 : Battery charge trasformer

G2 : Battery charge PCB

H2 : Voltage selector switch

I2 : 48V a.c. socket

L2 : Thermal relay

M2 : Contactor

N2 : G.F.I. and circuit breaker

O2 : 42V EEC socket

P2 : G.F.I. resistor

Q2 : T.E.P. engine protection

R2 : Solenoid control PCBT

S2 : Oil level transmitter

T2 : Engine stop push-button T.C.1

U2 : Engine start push-buttonT.C.1

V2 : 24V c.a. socket

Z2 : Thermal magnetic circuit breaker

W2 : S.C.R. protection unit

X2 : Remote control socket

Y2 : Remote control plug

A3 : Insulation moitoring

B3 : E.A.S. connector

C3 : E.A.S. PCB

D3 : Booster socket

E3 : Open circuit voltage switch

F3 : Stop push-button

G3 : Ignition coil

H3 : Spark plug

I3 : Range switch

L3 : Oil shut-down button

M3 : Battery charge diode

N3 : Relay

O3 : Resistor

P3 : Sparkler reactor

Q3 : Output power unit

R3 : Electric siren

S3 : E.P.4 engine protection

T3 : Engine control PCB

U3 : R.P.M. electronic regulator

V3 : PTO HI control PCB

Z3 : PTO HI 20 l/min push-button

W3 : PTO HI 30 l/min push-button

X3 : PTO HI reset push-button

Y3 : PTO HI 20 l/min indicator

A4 : PTO HI 30 l/min indicator

B4 : PTO HI reset indicator

C4 : PTO HI 20 l/min solenoid valve

D4 : PTO HI 30 l/ min solenoid valve

E4 : Hydraulic oil pressure switch

F4 : Hycraulic oil level gauge

G4 : Preheating glow plugs

H4 : Preheating gearbox

I4 : Preheating indicator

L4 : R.C. filter

M4 : Heater with thermostat

N4 : Choke solenoid

O4 : Step relay

P4 : Circuit breaker

Q4 : Battery charge sockets

R4 : Sensor, cooling liquid temperature

S4 : Sensor, air filter clogging

T4 : Warning light, air filter clogging

U4 : Polarity inverter remote control

V4 : Polarity inverter switch

Z4 : Transformer 230/48V

W4 : Diode bridge, polarity change

X4 : Base current diode bridge

Y4 : PCB control unit, polarity inverter

A5 : Base current switch

B5 : Auxiliary push-button ON/OFF

C5 : Accelerator electronic control

D5 : Actuator

E5 : Pick-up

F5 : Warning light, high temperature

G5 : Commutator auxiliary power

H5 : 24V diode bridge

I5 : Y/

commutator

L5 : Emergency stop button

M5 : Engine protection EP5

N5 : Pre-heat push-button

O5 : Accelerator solenoid PCB

P5 : Oil pressure switch

Q5 : Water temperature switch

R5 : Water heater

S5 : Engine connector 24 poles

T5 : Electronic GFI relais

U5 : Release coil, circuit breaker

V5 : Oil pressure indicator

Z5 : Water temperature indicator

W5 : Battery voltmeter

X5 : Contactor, polarity change

Y5 : Commutator/switch, series/parallel

A6 : Commutator/switch

B6 : Key switch, on/off

C6 : QEA control unit

D6 : Connector, PAC

E6 : Frequency rpm regulator

F6 : Arc-Force selector

G6 : Device starting motor

H6 : Fuel electro pump 12V c.c.

I6 : Start Local/Remote selector

L6 : Choke button

M6 : Switch CC/CV

N6 : Connector – wire feeder

O6 : 420V/110V 3-phase transformer

P6 : Switch IDLE/RUN

Q6 : Hz/V/A analogic instrument

R6 : EMC filter

S6 : Wire feeder supply switch

T6 : Wire feeder socket

U6 : DSP chopper PCB

V6 : Power chopper supply PCB

Z6 : Switch and leds PCB

W6 : Hall sensor

X6 : Water heather indicator

Y6 : Battery charge indicator

A7 : Transfer pump selector AUT-0-MAN

B7 : Fuel transfer pump

C7 : "GECO" generating set test

D7 : Flooting with level switches

E7 : Voltmeter regulator

F7 : WELD/AUX switch

G7 : Reactor, 3-phase

H7 : Switch disconnector

I7 : Solenoid stop timer

L7 : "VODIA" connector

M7 : "F" EDC4 connector

N7 : OFF-ON-DIAGN. selector

O7 : DIAGNOSTIC push-button

P7 : DIAGNOSTIC indicator

Q7 : Welding selector mode

R7 : VRD load

S7 : 230V 1-phase plug

T7 : V/Hz analogic instrument

U7 : Engine protection EP6

V7 : G.F.I. relay supply switch

Z7 : Radio remote control receiver

W7 : Radio remote control trasnsmitter

X7 : Isometer test push-button

Y7 : Remote start socket

A8 : Transfer fuel pump control

B8 : Ammeter selector switch

C8 : 400V/230V/115V commutator

D8 : 50/60 Hz switch

E8 : Cold start advance with temp. switch

F8 : START/STOP switch

G8 : Polarity inverter two way switch

H8 : Engine protection EP7

I8 : AUTOIDLE switch

L8 : AUTOIDLE PCB

M8 : A4E2 ECM engine PCB

N8 : Remote emergency stop connector

O8 : V/A digital instruments and led VRD

PCB

P8 : Water in fuel

Q8 : Battery disconnect switch

R8 : Inverter

S8 : Overload led

T8 : Main IT/TN selector

U8 : NATO socket 12V

V8 : Diesel pressure switch

Z8 : Remote control PCB

W8 : Pressure turbo protection

X8 : Water in fuel sender

Y8 : EDC7-UC31 engine PCB

A9 : Low water level sender

B9 : Interface card

C9 : Limit switch

D9 : Starter timing card

E9 : Luquid pouring level float

F9 : Under voltage coil

G9 : Low water level warning light

H9 : Chopper driver PCB

I9 : Fuel filter heater

L9 : Air heater

M9 : ON/OFF switch lamp

N9 : UP/DOWN button mast

O9 : Hydraulic unit solenoid valve

P9 : Hydraulic unit engine

Q9 : Ignitor

R9 : Lamp

S9 : Power system

T9 :

U9 :

V9 :

Z9 :

W9 :

X9 :

Y9 :

Summary of Contents for TS 400 PS-BC

Page 1: ...19 05 05 76440M00 preparato da UPT approvato da DITE USE AND MAINTENANCE MANUAL 764409003 GB 1 0 1 3 TS 400 PS BC PL 50Hz TS 500 PS BC PL 60Hz ...

Page 2: ......

Page 3: ...e assembling is made on a steel structure on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise CONNECTOR FOR REMOTE CONTROL BATTERY FILTER EXHAUST MUFFLER WELDING CURRENT REGULATION The engine driven welder has a base constructed in steel which includes the tank A cover which is hinged to the roll bar facilitates a rapid check for...

Page 4: ... continue to satisfy the needs of its clients aswell as to improve the transparency and thecom munications regarding all the company s activesin accordance with the official procedures and inhar mony 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 andth...

Page 5: ...BEFORE USE M 2 6 INSTALLATION AND ADVICE M 2 7 INSTALLATION M 2 7 1 DIMENSIONS M 3 UNPACKING M 4 TRANSPORT AND DISPLACEMENTS M 6 3 ASSEMBLY CTL22 M 20 SET UP FOR OPERATION M 21 STARTING AND STOPPING THE ENGINE M 31 CONTROLS M 32 USE AS A WELDER M 34 USE AS WELDER M 37 USE AS A GENERATOR M 40 TROUBLE SHOOTING M 43 MAINTENANCE M 44 1 PERIODICAL MAINTENANCE M 45 STORAGE M 46 CUST OFF M 55 RECOMMENDED...

Page 6: ...e matter In no case MOSA division of B C S S p A will be held 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 any responsibility about the shown information on firms or individuals but keeps the right to refuse services or information publication which it judges discutible unright or illegal 10 10 02 M1 01 G...

Page 7: ...ampness and heat You must take into account that some figures contained in it want only to identify the described parts and therefore might not correspond to the machine in your possession INFORMATION OF GENERAL TYPE In the envelope given together with the machine and or set you will find the manual for Use Maintenance and Spare Parts the manual for use of the engine and the tools if included in t...

Page 8: ... 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 Furthermore on each model it is shown the noise level value the symbol used is the following The indication is shown in a clear readable and indeleble way on a sticker TEMP C RPM n IP kW ALTIT Kg m G P F Hz V V I A KVA TYPE I CL SERIAL ...

Page 9: ... Marchio Brand Modello Model Matricola Serial number è conforme con quanto previsto dalle Direttive Comunitarie e relative modifiche est en conformité avec ce qui est prévu par les Directives Communautaires et relatives modifications conforms with the Community Directives and related modifications mit den Vorschriften der Gemeinschaft und deren Ergänzungen übereinstimmt in overeenkomst is met de i...

Page 10: ...ording to ISO 3046 1 temperature 25 C 30 relative humidity altitude 100 m above sea level It s admitted overload of 10 each hour every 12 h In an approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 C ACOUSTIC POWER LEVEL ATTENTION The concrete risk due to the machine depends on the conditions in which it is used Therefore it is up to the end user and under his...

Page 11: ... case Welding and Generation can be used simultaneously however the engine cannot be overloaded The table below gives the maximum limits to be respected OUTPUT CARACTERISTIC BC ARC FORCE WITH BASE CURRENT 19 05 05 76440 GB TECHNICAL DATA TS 400 PS TS 500 PS M 1 6 REV 1 02 09 I GB F 200 50 10 0 20 30 40 80 60 70 100 90 100 50 150 V V 300 250 350 400 450 I A WELDING CURRENT 250 A 200 A 150 A 100 A 0...

Page 12: ...o persons or things Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine SAFETY PRECAUTIONS This heading w...

Page 13: ...persons Use only with safety clothing It is compulsory to use the personal protection means given in equip ment Use only with safety clothing It is compulsory to use the personal protection means given in equipment Use only with safety protections It is a must to use protection means suitable for the different welding works Use with only safety material It is prohibited to use water to quench fire...

Page 14: ...etely Wipe up spilled fuel before starting engine An electric shock can kill 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 Skin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist Ingestion Do not induce vomit as to avoid the ...

Page 15: ... safe before starting any welding operation àDo not touch any bare wires leads or contacts as they may be live and there is danger of electric shock which can cause death or serious burns The electrode and welding cables etc are live when the unit is operating àDo not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes àInsulate yourself from the w...

Page 16: ...e a dangerous increase of the temperature Make sure that the machine does not move during the work block it possibly with tools and or devices made to this purpose Maximum leaning of the machine in case of dislevel 10 10 20 max 10 10 20 max 26 11 99 M2 6GB 1 5 m 1 5 m 1 5 m GAS DI SCARICO EXHAUST OUTPUT MOVES OF THE MACHINE At any move check that the engine is off that there are no connections wit...

Page 17: ...12 04 05 76440 I Installazione Installation Installation TS 400 PS TS 500 PS M 2 7 REV 0 06 08 I GB F Luftzirkulation Instalación D E NL ...

Page 18: ...12 04 05 76440 I TS 400 PS TS 500 PS M 2 7 1 REV 0 04 05 30 32 5 760 205 1300 57 5 30 1110 735 1000 1720 SILENCED CHECKOIL DAILY Dimensioni Dimensions Dimensions I GB F Abmessungen Dimensiones D E NL ...

Page 19: ...n rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or absence of parts envelopes manuals etc we advise you to inform immediately our Technical Service For eliminating the packing materials the User must 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 us...

Page 20: ...es 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 no CTL accessory If you did not keep to the instructions you could damage the structure of the machine DANGER LIFTING EY...

Page 21: ...arts 3 Open the jaw so as to let the foot sprag 4S go through 4 Introduce into the jaw 3 the upper part 4S of the foot and block momentaneously with the lever 4L the whole foot 6 Assemble on the machine the towbar 5 complete of foot with the screws nuts and washers 7 Assemble the axle 7 to the base of the machine with the screws and relative washers two per part so that their supports coincide 8 I...

Page 22: ...the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY FUEL Refill the tank with good quality diesel fuel such as automobile type diesel fuel for example For further details on the type of diesel fuel to use see the motor operating manual suppli...

Page 23: ...ot an easy job A lack in tacking these precautions would result in the mix of different additives used in different coolants which would originate gelatinous substances capable of obstructing the cooling system GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a diffe rential switch circuit breaker In these groups the generator star...

Page 24: ...t up without problems down to temperatures of 10 C 15 C In case of starting difficulty it is possible to repe at the starting preheating for a max time of 10 seconds For start up and use at lower tempe ratures please see the engine manual or turn to our Technical Assistance Center In case of unsuccessful start up do not in sist for longer than 5 seconds Wait 10 15 seconds before attempting another...

Page 25: ...B5 Auxiliary current push button C2 Fuel level light C3 E A S PCB C6 Control unit for generating sets QEA D Ground fault interrupter 30 mA D1 Engine control unit and economiser EP1 D2 Ammeter E2 Frequency meter E6 Frequency rpm regulator E7 Voltmeter regulator F Fuse F3 Stop switch F5 Warning light high temperature F6 Arc Force selector G1 Fuel level transmitter H2 Voltage commutator H6 Fuel elect...

Page 26: ... 5KVA 0 1 2 1 1 0 0000101 h TELECOMANDO REMOTE CONTROL OFF ON MAX A 200 A FUSE 5x20 0 1A ARC FORCE OFF ON 20 400A FUEL 500 MAX 10 SEC POLARITY SWITCH FUSE V 0 1 2 1 1 400T230M48M VERSION 400T230M110M VERSION S1 22 24B 26 G1 23 24 ONLYGOUGING S EMERGENCY NO PL VERSION 15 I2 F M C2 D F6 X1 I3 N T N1 F5 M1 59A 59D I4 59B 9 9 10 12 L5 W1 O1 31 27 15 Q1 59B Comandi Controls Commandes I GB F D E NL Mand...

Page 27: ...ng light If on during the group s operation indicates a malfunction in the motor s battery charge circuit M1 Low fuel warning light If on indicates the fuel in the tank has reached the low level point C2 Fuel level indicator Indicates the percen tage of fuel in the fuel tank D E V OFF ON START 4 4 0 I3 Switch for welding scale reduction Placed on 200Ait limits the maximum value of the welding curr...

Page 28: ...sure the working of varius electric protection devices referring to the several distribution system TT TN IT operation unnecessary for machine with isometer Fully insert the welding cable plugs into the corre sponding sockets only gauging 9 10 turning them clockwise to lock them in position Make sure that the ground clamp whose ca ble must be connected to the or terminal depending on the type of e...

Page 29: ...s short circuited POLARITY INVERTER PL VERSION lt permits to have at the electrode holder the positive or negative polarity of the welding diode bridge It is used above all in the first run with cellulosic electrodes to lower the bath temperature and so doing ease up the welding on pipes of small thickness BASIC CURRENT BC Positioning the switch on ON is obtained a low voltage welding current whic...

Page 30: ...USE AS A GENERATOR 19 05 05 76440 GB I GB F TS 400 PS TS 500 PS M 37 REV 0 05 05 0 10 0 10 0 10 0 10 110V 230V 230V 400V THERMOPROTECTION If you overload the genset the thermoprotection will automatically switch off lf the thermoprotection is released disconnect all the connected loads Reset the thermoprotection pressing the central pole CLOSED OPEN When reset connect the loads again In case the p...

Page 31: ...ted 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 position Position welding current adjusting T knob at the necessary current value for the diameter and type of electrode ON OFF 09 11 99 M38GB PUSH AND SCREW TIGHT ...

Page 32: ...in operation when the engine starts and in case of low oil pressure and high temperature will stop the machine and show the cause of the stop with the warning light of high temperature or low oil pressure In case of low oil pressure check the level and if it is correct call the Service Station In case of high temperature make sure that there are no leaves and or pieces of material obstructing the ...

Page 33: ...sure that it is discharged disconnect all wires from condenser and using an ohmmeter check that the condenser is not short circuited 3 If the condenser box is OK disconnect all leads from the stator except for those going to the condenser box and check the output from the alternator If there is no output from the welding winding and the auxiliary winding replace the stator 4 If there is output fro...

Page 34: ...rry out de aeration on the fuel system See engine operating manual 3 Replace In case the problem persists check the electrical circuit and eliminate the problem Call an authorised service centre 1 Check oil level 2 Replace the malfunctioning sensor 3 Replace the protection 4 Replace 1 Engine temperature too high or insufficient oil pressure 2 High temperature sensor or oil pressure defective 3 ES ...

Page 35: ...DO NOT USE COMPRESSED AIR DECALS AND LABELS All warning and decals should be checked once a year and replaced if missing or unreadable STRENUOUS OPERATING CONDITIONS Under extreme operating conditions frequent stops and starts dusty environment cold weather extended periods of no load operation fuel with over 0 5 sulphur content do maintenance more frequently BATTERY WITHOUT MAINTENANCE DO NOT OPE...

Page 36: ... the concentration of the coolant 1 l Check the tension and the state of the driving belt l Replace the control belt of the alternator l Drain the water from the prefilter if assembled l Replace the cartridge of the fuel filter l Check the efficiency of the injectors 2 l Check the level of the lubricating oil l Change the lubricating oil of the engine fill slowly make shure the right quantity is u...

Page 37: ...an the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in o dry place DIESEL ENGINE For short periods of time it is advisable about every 10 days to make the machine work with load for 15 30 minutes for a correct distribution of the lubricant to re charge the battery and to prevent any possible bloking of the injection system For long pe...

Page 38: ...the various components of the machine must be made accordingly to rules in force of law a o local rules Particular attention must be paid when getting rid of lubricating oils battery electrolyte and infla mable liquids such as fuel cooling liquid The machine user is responsible for the observance of the norms concerning the environment conditions with regard to the elimination of the machine being...

Page 39: ... ground clamp Special for steels run on pipes with R max 55 kg mm2 Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS E X X Y Z 2 digits type of coating and electric power con ditions see table 3 1 digits welding positions see table 2 2 3 digits tesile strenght of the weld deposit see table 1 symbol for Coated electrode Table 1 Table 2 Table 3 10 10 03 M55GB ...

Page 40: ...V4 Polarity inverter switch Z4 Transformer 230 48V W4 Diode bridge polarity change X4 Base current diode bridge Y4 PCB control unit polarity inverter A5 Base current switch B5 Auxiliary push button ON OFF C5 Accelerator electronic control D5 Actuator E5 Pick up F5 Warning light high temperature G5 Commutator auxiliary power H5 24V diode bridge I5 Y s commutator L5 Emergency stop button M5 Engine p...

Page 41: ......

Page 42: ...12 04 05 76440 I TS 400 PS TS 500 PS M 61 1 REV 1 09 10 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 43: ...12 04 05 76440 I TS 400 PS TS 500 PS 400T230M110M M 61 2 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 44: ...12 04 05 76440 I TS 400 PS 50 Hz 400T230M48M M 61 3 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 45: ...12 04 05 76440 I TS 400 PS BC TS 500 PS BC TS 600 PS BC M 61 4 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 46: ...12 04 05 76440 I TS 400 PS PL TS 500 PS PL M 61 5 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 47: ...12 04 05 76440 I TS 400 PS BC TS 500 PS BC M 61 6 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 48: ...12 04 05 76440 I TS 400 PS PL TS 500 PS PL M 61 7 REV 0 04 05 Schema elettrico Electric diagram Schemas electriques I GB F D E NL Stromlaufplan Esquema eléctrico ...

Page 49: ......

Page 50: ...MOSA div della BCS S p A Stabilimento di Viale Europa 59 20090 Cusago MI Italia Tel 39 0290352 1 Fax 39 0290390466 ...

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