Mosa DSP 2x400 PSX Maintance Manual

DSP 2x400 PSX
884129003 - GB0 4 0 8
USE AND MAINTENANCE MANUAL
28/11/05 88412M00 preparato da UPT approvato da DITE
SPARE PARTS CATALOG
© MOSA 1.2-05/03
Quality system GE_, MS_, TS_, EAS_
M
01
UNI EN ISO 9001 : 2000
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 ) -
www.icim.it
10/10/02 M01-GB
INDEX DSP 2x400 PSX
© MOSA REV.1-04/08
M 01 QUALITY SYSTEM M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARK M 1.5 TECHNICAL DATA
M 2 .... SYMBOLS AND SAFETY PRECAUTIONS
M 2.3 -…. ABBREVIATIONS LEGEND M 2.5 -…. INSTALLATION AND ADVICE BEFORE USE M 2.6 INSTALLATION AND ADVICE M 3 UNPACKING M 4.2 TRANSPORT AND DISPLACEMENTS COVERED UNITS M 6.8 ASSEMBLY CTL
M 20.... PREPARING THE UNIT
M 21 START-UP M 22 SHUTTING DOWN THE MOTOR M 31 CONTROLS M 32 USE AS A WELDER M 33... WELDER DSP (USE) M 37 USING THE GENERATOR M 38.9 REMOTE CONTROL M 40.1 TROUBLESHOOTING M 43… MAINTENANCE M 45 STORAGE M 46 CUST OFF M 52 TECHNICAL DATA M 55 RECOMMENDED ELECTRODES M 60 ELECTRICAL SYSTEM LEGENDE M 61-….. ELECTRICAL SYSTEM
M
1
ED... SPARE PARTS
28/11/05 88412-GB
Copyright GE_, MS_, TS_, EAS
© MOSA 1.0-10/02
ATTENTION
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).
© All rights are reserved to said Company.
It is a property logo of MOSA division of B.C.S. S.p.A. All other possible logos contained in the 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.
10/10/02 M1-01-GB
© MOSA 1.0-10/02
Notes GE_, MS_, TS_, EAS_
M
1-1
INFORMATION
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.
10/10/02 M 1-1 GB
M
CE MARK
© MOSA REV.4-10/07
1.4
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.
10/10/02 M1-4 GB
M
DSP 2x400 PSX
© MOSA REV.1-04/08
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 data DSP 2x400 PS
GENERATOR
Output three-phase 40 kVA / 400 V / 58 A Output single-phase 20 kVA / 230 V / 87 A Output single-phase 5 kVA / 48 V / 104 A Frequency 50 Hz
ϕϕ
Cos
ϕ 0.8
ϕϕ
ALTERNATOR Self-excited, self-regulated, brushless
Type three-phase, asynchronous Insulating class H
ENGINE
Mark PERKINS Model 1103A-33TG1
Type 4-Stroke
Displacement 3300 cm Cylinders 3 Output max 45.6 kW (62.1 HP) Speed 1500 rpm Fuel consumption 215 g/kWh Cooling system water Cooling system capacity 10.2 l Engine oil capacity 7.9 l Starter Electric Fuel Diesel
GENERAL SPECIFICATIONS
Battery 12V - 100Ah Tank capacity 102 l Running time (at duty cycle 60%) 13 h Protection IP 44 Dimensions Lxwxh (mm) * 2490x1030x1300 (1480) Weight * 1300 Kg Noise level 94 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
2000/ 14 / CE
according to 2000/14/CE directive.
28/11/05 88412-GB
© MOSA 1.0-11/05
C.C. WELDING
Welding current 2x400A/35% - 2x360A/60% - 2x330A/100% Starting voltage 68V
C.V. WELDING
Welding current 2x360A/60% - 2x330A/100% Welding voltage 16 - 36V
TECHNICAL DATA
DSP 2x400 PSX
C.C.
M
1.5.1
70
60
50
40
30
20
10
STATIC CHARACTERISTIC
V
C.C.
C.C.
C.C. TIG
C.V.
max
min.
A
10
100 200
300 400 500
SIMULTANEOUS UTILIZATION FACTORS
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:
WELDING CURRENT
SINGLE POSITION
AUXILIARY POWER
WELDING CURRENT
DOUBLE POSITION
AUXILIARY POWER
300A400A
35 kVA30kVA25kVA
40 kVA 40 kVA
2x300A2x400A 02x200A 2x100A
30 kVA20 kVA10kVA 40 kVA 40 kVA
0200A 100A
28/11/05 88412-GB
© MOSA 1.0-11/99
SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_
M
2
SYMBOLS IN THIS MANUAL
- 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.
26/11/99 M2GB
© MOSA 1.1-04/03
SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_
M
2-1
SYMBOLS (for all MOSA models)
STOP - Read absolutely and be duly attentive
Read and pay due attention
GENERAL ADVICE - If the advice is not respected damage can happen to persons or things.
HIGH VOLTAGE - Attention High Voltage.There can be parts in voltage, dangerous to touch. The non observance of the advice implies life danger.
FIRE - Danger of flame or fire. If the advice is not respected fires can happen.
HEAT - Hot surfaces. If the advice is not respected burns or damage to things can be caused.
EXPLOSION - Explosive material or danger of explosion. in general. If the advice is not respected there can be explosions.
WATER - Danger of shortcircuit. If the advice is not respected fires or damage to persons can be caused.
SMOKING - The cigarette can cause fire or explosion. If the advice is not respected fires or explosions can be caused.
ACIDS - Danger of corrosion. If the advice is not respected the acids can cause corrosions with damage to persons or things.
PROHIBITIONS No harm for persons
Use only with safety clothing -
It is compulsory to use the personal protection means given in equipment.
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 fires on the electric machines.
Use only with non inserted voltage -
It is prohibited to make interventions before having disinserted the voltage.
No smoking -
It is prohibited to smoke while filling the tank with fuel.
No welding -
It is forbidden to weld in rooms containing explosive gases.
ADVICE No harm for persons and things
Use only with safety tools, adapted to the specific use -
It is advisable to use tools adapted to the various maintenance works.
Use only with safety protections, specifically suitable
It is advisable to use protections suitable for the different welding works.
Use only with safety protections -
It is advisable to use protections suitable for the different daily checking works.
WRENCH - Use of the tools. If the advice is not respected damage can be caused to things and even to persons.
PRESSION - Danger of burns caused by the expulsion of hot liquids under pressure.
ACCES FORBIDDEN to non authorizad peaple.
Use only with safety protections -
It is advisable to use all protections while shifting the machine.
Use only with safety protections -
It is advisable to use protections suitable for the different daily checking works.and/or of maintenance.
26/11/99 M2-1GB
INSTALLATION AND ADVICE BEFORE USE GE_, MS_, TS_
© MOSA 1.0-06/00
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.
WARNING
CAUTION
DANGEROUS
WARNING
THE MACHINE MUST NOT BE USED IN AREAS WITH
EXPLOSIVE ATMOSPHERE
10/06/00 M2-5I
M
PRECAUTION (ENGINE DRIVEN WELDER) GE_, MS_, TS_
© 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 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-
flamable protective clothers).
30/03/00 M2-5GB
© MOSA 1.0-11/99
INSTALLATION AND ADVICE GE_, MS_, TS_
M
2.6
INSTALLATION AND ADVICE BEFORE USE
GASOLINE ENGINES
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".
26/11/99 M2-6GB
© MOSA 1.0-11/05
Installazione Installation Installation
Luftzirkulation M
DSP 2x400 PSX
2.7
18/11/05 88412-I
© MOSA 1.1-02/04
UNPACKING GE_, MS_, TS_
NOTE
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 SKID GE_, MS_, TS_M4-2
© 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 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
no
petrol in its tank,
no
oil in the engine and and electrolyte in the
30/03/00 M4GB
CTL 35 -45 - 50 - 95
5
5
ASSEMBLY
© MOSA 1.1-04/06
M
6.8
ATTENTION
The CTL accessory cannot be removed from the machine and used separately (actioned manually or following vehicles) for the transport of loads or anyway for used different from the machine movements.
TRAILERS
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a maximum speed of 40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type IS EXCLUDED, 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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