MOSA has certified its quality system according to
UNI EN ISO 9001:2000 to ensure a constant, high
quality of its products. This certification covers the
design, production and servicing of engine driven
welders and generating sets.
The certifying institute, ICIM, which is a member of
the International Certification Network IQNet,
awarded the official approval to MOSA after an
examination of its operations at the head office and
plant in Cusago (MI), Italy.
This certification is not a point of arrival but a pledge
on the part of the entire company to maintain a level
of quality of both its products and services which
will continue to satisfy the needs of its clients, as
well as to improve the transparency and the
communications regarding all the company’s actives
in accordance with the official procedures and in
harmony with the MOSA Manual of Quality.
The advantages for MOSA clients are:
· Constant quality of products and services at the
high level which the client expects;
· Continuous efforts to improve the products and
their performance at competitive conditions;
· Competent support in the solution of problems;
· Information and training in the correct application
and use of the products to assure the security of
the operator and protect the environment;
· Regular inspections by ICIM to confirm that the
requirements of the company’s quality system
and ISO 9001 are being respected.
All these advantages are guaranteed by the
CERTIFICATE OF QUALITY SYSTEM No.0192
issued by ICIM S.p.A. - Milano (Italy ) -
M 01QUALITY SYSTEM
M 1.01COPYRIGHT
M 1.1NOTES
M 1.4CE MARK
M 1.5TECHNICAL DATA
M 2 ....SYMBOLS AND SAFETY PRECAUTIONS
M 2.3 -…. ABBREVIATIONS LEGEND
M 2.5 -…. INSTALLATION AND ADVICE BEFORE USE
M 2.6INSTALLATION AND ADVICE
M 3UNPACKING
M 4.2TRANSPORT AND DISPLACEMENTS COVERED UNITS
M 6.8ASSEMBLY CTL
M 20....PREPARING THE UNIT
M 21START-UP
M 22SHUTTING DOWN THE MOTOR
M 31CONTROLS
M 32USE AS A WELDER
M 33...WELDER DSP (USE)
M 37USING THE GENERATOR
M 38.9REMOTE CONTROL
M 40.1TROUBLESHOOTING
M 43…MAINTENANCE
M 45STORAGE
M 46CUST OFF
M 52TECHNICAL DATA
M 55RECOMMENDED ELECTRODES
M 60ELECTRICAL SYSTEM LEGENDE
M 61-…..ELECTRICAL SYSTEM
This use and maintenance manual is an important
part of the machines in question.
The assistance and maintenance personel must
keep said manual at disposal, as well as that for
the engine and alternator (if the machine is
synchronous) and all other documentation about the
machine.
We advise you to pay attention to the pages
concerning the security (see page M1.1).
It is a property logo of MOSA division of B.C.S.
S.p.A. All other possible logos contained in the
documentation are registered by the respective
owners.
M
1.01
The reproduction and total or partial use, in
➠
any form and/or with any means, of the
documentation is allowed to nobody without a
written permission by MOSA division of B.C.S.
S.p.A.
To this aim is reminded the protection of the author’s
right and the rights connected to the creation and
design for communication, as provided by the laws
in force in the 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.
Dear Customer,
We wish to thank you for having bought from
MOSA a high quality set.
Our sections for Technical Service and Spare
Parts will work at best to help you if it were
necessary.
To this purpose we advise you, for all control and
overhaul operations, to turn to the nearest
authorized Service Centre, where you will obtain
a prompt and specialized intervention.
In case you do not profit on these Services and
☞
some parts are replaced, please ask and be
sure that are used exclusively original MOSA
parts; this to guarantee that the performances
and the initial safety prescribed by the norms in
force are re-established.
The use of non original spare parts will cancel
☞
immediately any guarantee and Technical Service obligation from MOSA.
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 the
equipment), the guarantee (in the countries where
it is prescribed by law).
Our products have been designed for the use of
generation for welding, electric and hydraulic
system; ANY OTHER DIFFERENT USE NOT
INCLUDED IN THE ONE INDICATED, relieves
MOSA from the risks which could happen or,
anyway, from that which was agreed when selling
the machine; MOSA excludes any responsibility
for damages to the machine, to the things or to
persons in this case.
Our products are made in conformity with the
safety norms in force, for which it is advisable to
use all these devices or information so that the
use does not bring damage to persons or things.
NOTES ABOUT THE MANUAL
Before actioning the machine please read this
manual attentively. Follow the instructions
contained in it, in this way you will avoid
inconveniences due to negligence, mistakes or
incorrect maintenance. The manual is for qualified
personnel, who knows the rules: about safety and
health, installation and use of sets movable as
well as fixed.
You must remember that, in case you have
difficulties for use or installation or others, our
Technical Service is always at your disposal for
explanations or interventions.
The manual for Use Maintenance and Spare Parts
is an integrant part of the product. It must be kept
with care during all the life of the product.
In case the machine and/or the set should be
yielded to another user, this manual must also
given to him.
Do not damage it, do not take parts away, do not
tear pages and keep it in places protected from
dampness and heat.
While working it is advisable to keep to the
personal safety norms in force in the countries to
which 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 potential
intervention will fall on the executioner as in fact
he becomes maker of the machine.
Notice: this manual does not engage MOSA,
☞
who keeps the faculty, apart the essential
characteristics of the model here described and
illustrated, to bring betterments and modifications
to parts and accessories, without putting this
manual uptodate immediately.
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.
Any of our product is labelled with CE marking attesting its conformity to appliable directives
and also the fulfillment of safety requirements of the product itself; the list of these directives is
part of the declaration of conformity included in any machine standard equipment.
Here below the adopted symbol:
CE marking is clearly readable and unerasable and it can be either part of the data-plate (A) or
placed as a sticker near the data-plate (B)
A
B
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.
The DSP 2x400 engine driven welder ia a unit which ensures the function as:
a) a current source for arc welding
b) a current source for the auxiliary power generation
It is meant for industrial and professional use, powered by an endothermic engine; it is composed of
various 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 also
eliminate sounds which would produce noise.
TECHNICAL DATA
1.5
Technical dataDSP 2x400 PS
GENERATOR
Output three-phase40 kVA / 400 V / 58 A
Output single-phase20 kVA / 230 V / 87 A
Output single-phase5 kVA / 48 V / 104 A
Frequency50 Hz
ϕϕ
Cos
ϕ0.8
ϕϕ
ALTERNATORSelf-excited, self-regulated, brushless
Typethree-phase, asynchronous
Insulating classH
ENGINE
MarkPERKINS
Model1103A-33TG1
Type4-Stroke
Displacement3300 cm
Cylinders3
Output max45.6 kW (62.1 HP)
Speed1500 rpm
Fuel consumption215 g/kWh
Cooling systemwater
Cooling system capacity10.2 l
Engine oil capacity7.9 l
StarterElectric
FuelDiesel
GENERAL SPECIFICATIONS
Battery12V - 100Ah
Tank capacity102 l
Running time (at duty cycle 60%)13 h
ProtectionIP 44
Dimensions Lxwxh (mm) *2490x1030x1300 (1480)
Weight *1300 Kg
Noise level94 LWA (69 dB(A))
* Dimensions and weight are inclusive of all parts without wheels and towbar.
3
OUTPUT
Declared power according to ISO 8528-1 (temperature 25°C, 30% relative hummidity, altitude 100 m above sea level).
(*Stand-by) = maximum available power for use at variable loads for a yearly number of hours limited at 500 h. No overload is
admitted.
(**Prime power P.R.P.) = maximum available power for use at variable loads for a yearly illimited number of hours. The average
power to be taken during a period of 24 h must not be over 80% of the P.R.P.
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 direct responsibility to make a correct evaluation of the same risk and to adopt specific precautions (for
instance, adopting a I.P.D. -Individual Protection Device)
Acoustic Noise Level (LWA) - Measure Unit dB(A): it stands for acoustic noise released in a certain delay of time. This is not
submitted to the distance of measurement.
Acoustic Pressure (Lp)- Measure Unit dB(A): it measures the pressure originated by sound waves emission. Its value
changes in proportion to the distance of measurement.
The here below table shows examples of acoustic pressure (Lp) at different distances from a machine with Acoustic Noise
Level (LWA) of 95 dB(A)
Lp a 1 meter = 95 dB(A) - 8 dB(A) = 87 dB(A)Lp a 7 meters = 95 dB(A) - 25 dB(A) = 70 dB(A)
Lp a 4 meters = 95 dB(A) - 20 dB(A) = 75 dB(A)Lp a 10 meters = 95 dB(A) - 28 dB(A) = 67 dB(A)
PLEASE NOTE: the symbol when with acoustic noise values, indicates that the device respects noise emission limits
In case Welding and Generation can be used simultaneously, however, the engine cannot be overloaded.
The table below gives the maximum limits to be respected:
- The symbols used in this manual are designed to call
your attention to important aspects of the operation of
the machine as well as potential hazards and dangers
for persons and things.
IMPORTANT ADVICE
- Advice to the User about the safety:
N.B.: The information contained in the manual can
☞
be changed without notice.
Potential damages caused in relation to the use of
these instructions will not be considered because
these are only indicative.
Remember that the non observance of the
indications reported by us might cause damage to
persons or things.
It is understood, that local dispositions and/or laws
must be respected.
SAFETY PRECAUTIONS
DANGEROUS
This heading warns of an immediate danger for persons
as well for things. Not following the advice can result in
serious injury or death.
WARNING
This heading warns of situations which could result in
injury for persons or damage to things.
CAUTION
To this advice can appear a danger for persons as well as
for things, for which can appear situations bringing material damage to things.
IMPORTANT
WARNING
Situations of danger - no harm to 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.
NOTE
ATTENTION
These headings refer to information which will assis you
in the correct use of the machine and/or accessories.
The installation and the general advice concerning the operations, are finalized to the correct use of the
machine, in the place where it is used as generator group and/or welder.
M
2-5
Stop engine when fueling
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.
ENGINE
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
FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas
☞
or whatever event which may cause serious injuries or death, predispose the first aid in accordance with
the ruling labour accident standards or of local instructions.
Skin contact
Eyes contact
Ingestion
Suction of liquids from
lungs
Inhalation
Wash with water and soap
Irrigate with plenty of water, if the irritation persists contact a specialist
Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor
If you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take the
subject to the hospital with the utmost urgency
In case of exposure to high concentration of vapours take immediately to a non polluted zone
the person involved
Do not touch electric devices if you
are barefoot or with wet clothes.
Always keep off leaning surfaces
during work operations
Static electricity can demage the
parts on the circuit.
CHECKING BOARD
An electric shock can kill
FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable to
☞
cause severe wounds or death, follow the first aid as described by the ruling norms or local ones.
Appropriated
Not to be used
Other indications
Particular protection
Useful warnings
EXTINCTION MEANS
Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Avoid the use of water jets
Cover eventual shedding not on fire with foam or sand, use water jets to cool off the
surfaces close to the fire
Wear an autorespiratory mask when heavy smoke is present
Avoid, by appropriate means to have oil sprays over metallic hot surfaces or over electric
contacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep in
mind that the inflamability point is very low.
The operator of the welder is responsible for the security of the people who work with the welder and for those in the
vicinity.
The security measures must satisfy the rules and regulations for engine driven welders.
The information given below is in addition to the local security norms.
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.
2-5-1
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 shock
➠
which can cause death or serious burns. The electrode and welding cables, etc. are live when the unit is
operating.
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 avoid
➠
physical 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-
■ Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far from
the work area.
DIESEL ENGINES
■ Use in open space, air swept or vent exhaust gases
far from the work area.
Check that the air gets changed completely and the hot
air sent out does not come back inside the set so as to
cause a dangerous increase of the temperature.
1,5 m
1,5 m
1,5 m
GAS DI SCARICO
EXHAUST OUTPUT
Make sure that the machine does not move during
☞
the work: block it possibly with tools and/or devices
made to this purpose.
MOVES OF THE MACHINE
At any move check that the engine is off, that there
☞
are no connections with cables which impede the
moves.
POSITION
Place the machine on a level surface at a distance of at
least 1,5 m from buildings or other plants.
Maximum leaning of the machine (in case of dislevel)
PLACE OF THE MACHINE
In spots where it often rains and/or there are
flooded areas, do
■ in the bad weather
■ in flooded places.
not put the machine:
Protect all the electric parts at risk, because water
infiltrations could cause short circuits with damages
at persons and/or things.
The protection degree of the machine is put on the data
plate and in this manual at page "Technical Data".
Be sure that the lifting devices are: correctly mounted,
☞
adequate for the weight of the machine with it’s
packaging, and conforms to local rules and regulations.
When receiving the goods make sure that the product has not suffered damage during the transport,
that there has not been rough handling or taking
away of parts contained inside the packing or in the
set.
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.
M
3
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 the
machine, the data plate.
30/03/00 M3GB
TRANSPORT AND DISPLACEMENTS COVERED UNITS AND SKIDGE_, MS_, TS_M4-2
In case you should transport or move the machine, keep to the instructions as per the figures.
Make the transportation when the machine has
battery.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging, and
conform to local rules and regulations.
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
CTL accessory).
If you did not keep to the instructions, you could damage the structure of the machine.
FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with no
The CTL accessory cannot be removed from the machine and used separately (actioned manually or
following vehicles) for the transport of loads or anyway for used different from the machine movements.
TRAILERS
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a maximum speed
of 40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type ISEXCLUDED, because not in possesion of the requirements by
national and foreign traffic norms.
Nota: Lift the machine and assemble the parts as shown in the drawing
CTL 35-50
COMANDS
CTL 95
CTL 45
CTL 35-50
For assembling the generating set on the trolley CTL 35-45 50 - 95 please keep to following instructions:
1) - Lift thr generating set (by means of suitable hook)
6) - Assemble on the machine the towbar (5) complete of
foot with the M10x20 screws,nuts and washers.
7) - Assemble the axle (7) to the base of the machine with
the M10x20 screws and relative washers (two per
part) so that their supports coincide.
8) - Insert the wheel (9) on the axle then twist the
selfblocking nut (8).
9) - Pump the tyre (9) bringing the pressure to 4 atms for
the CTL 35-45-50 and 5/6 for the CTL 95.
10) - Lower the machine to the ground and place the parking
foot definitively (regulating at the best height).
ATTENTION
Do not substituite the original tires with other types.
CTL 45-95
9
7
8
30/03/04 M6GB
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