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Codice
Code
359319003
GE 12000 KSX / GS
Codigo
Kodezahl
M A D E I N I T A L Y
FILTER
BATTERY
MUFFLER
The unit is composed of: a structured base which includes a tank, an engine/alternator unit
08/04/14 35931-GB
fixed on the base by 3 elastic dampers, a roll-bar, with hook for an easy and sure lifting, a chest
hinged to the base for a quick access to the engine, to the air filter and to the battery. The set is
completed by a frontal panel where the sockets, the protections and the measur ing instruments
are mounted, all this protected by a same sized cover.
MOSA has certified its quality system according The advantages for MOSA clients are:
to UNI EN ISO 9001:2008 to ensure a constant, ·Constant quality of products and services at thehigh
highquality of its products. This certification covers level which the client expects;
thedesign, production and servicing of engine dri-
venwelders and generating sets. · Continuous efforts to improve the products andtheir
performance at competitive conditions;
The certifying institute, ICIM, which is a member
· Competent support in the solution of problems;
ofthe International Certification Network IQNet,
awarded the official approval to MOSA after an- · Information and training in the correct applicatio-
examination of its operations at the head office nand use of the products to assure the security
andplant in Cusago (MI), Italy. ofthe operator and protect the environment;
· Regular inspections by ICIM to confirm that the-
This certification is not a point of arrival but a
requirements of the company’s quality systemand
pledgeon the part of the entire company to maintain ISO 9001 are being respected.
a levelof quality of both its products and services
whichwill continue to satisfy the needs of its clients, All these advantages are guaranteed by the CER-
aswell as to improve the transparency and thecom- TIFICATE OF QUALITY SYSTEM No.0192 issued
munications regarding all the company’s activesin by ICIM S.p.A. - Milano (Italy ) - www.icim.it
accordance with the official procedures and inhar-
mony with the MOSA Manual of Quality.
10/10/02 M01-GB
M 01 QUALITY SYSTEM
M 1.01 COPYRIGHT
M 1.1 NOTES
M 1.4 CE MARK
M 1.4.1 DECLARATION OF CONFORMITY
M 1.5 TECHNICAL DATA
M 2 ADVICE
M 2.1 SYMBOLS
M 2.6 INSTALLATION AND ADVICE
M 2.7 INSTALLATION
M 2.7.1 DIMENSIONS
M3 UNPACKING
M 4.1 TRANSPORT
M 6.4 ASSEMBLY CTM - CTL
M 20.... SET-UP FOR OPERATION
M 21 STARTING
M 22 STOPPING
M 31 CONTROLS
M 37... USE AS A GENERATOR
M 38 REMOTE CONTROL
M 39.4 ENGINE PROTECTION ES - EV
M 40... TROUBLE SHOOTING
M 43 -….. MAINTENANCE
M 45 STORAGE
M 46 CUST OFF
M 60 ELECTRICAL SYSTEM LEGEND
M 61-….. ELECTRICAL SYSTEM
08/04/14 35931-GB
! 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.
+The use of non original spare parts will cancel While working it is advisable to keep to the personal safety
immediately any guarantee and Technical Service norms in force in the countries to which the product is
obligation. destined (clothing, work tools, etc.).
NOTES ABOUT THE MANUAL Do not modify for any motive parts of the machine (faste-
Before actioning the machine please read this manual nings, holes, electric or mechanical devices, others..) if
attentively. Follow the instructions contained in it, in this not duly authorized in writing: the responsibility coming
way you will avoid inconveniences due to negligence, from any potential intervention will fall on the executioner
mistakes or incorrect maintenance. The manual is for as in fact he becomes maker of the machine.
qualified personnel, who knows the rules: about safety
and health, installation and use of sets movable as well
as fixed.
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.
TYPE
SERIAL N° Made in UE-ITALY
TYPE/N°
VOLTAGE(V)
POWER(W)
Hz KVA
P.F. V(V)
G I(A)
I.CL.
LTP POWER IN ACCORDANCE WITH ISO 8528
n RPM TEMP. °C IP
Pmax kW ALTIT. m Kg
Furthermore, on each model it is shown the noise level value; the symbol used is the following:
10/10/02 M1-4 GB
DICHIARAZIONE DI CONFORMITA'
Marchio / Brand :
Modello / Model :
ing. Benso Marelli - Consigliere Delegato / Managing Director ; V.le Europa 59, 20090 Cusago (MI) – Italy
_______________
Cusago, Ing. Benso Marelli
Consigliere Delegato
04/06/10 M1.4.1
Managing Director
MM 083.1
The generating set GE 12000 is a unit which transforms the mechanical energy, generated by endothermic engine, into electric
energy, through an alternator.
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.
OUTPUT
Declared power according to ISO 8528-1 (temperature 25°C, 30% relative humidity, 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 PRP) = 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 PRP.
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.
PLEASE NOTE: the symbol when with acoustic noise values, indicates that the device respects noise emission limits
2000 / 14 / CE
The installation and general warnings regarding operations are aimed achieving correct use of the machine and/or
apparatus in the place where it is used as a genset and/or motor welder.
- Advice to the User about the safety:
+ NB: The information contained in the manual can be changed without notice.
Any damage caused in connection with the use of these instructions shall not be considered as they 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.
! IMPORTANT
These headings refer to information which will assis you
! NOTE in the correct use of the machine and/or accessories.
! ATTENTION
+ 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.
+ 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.
EXTINCTION MEANS
Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Not to be used Avoid the use of water jets
Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces close to the fire
Particular protection Wear an autorespiratory mask when heavy smoke is present
10/06/00 M2GB
Useful warnings 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.
Read and pay due attention Use only with safety clothing -
It is compulsory to use the personal protection
means given in equipment.
WRENCH - Use of the tools. If the advice is Use only with safety protections -
not respected damage can be caused to things It is advisable to use all protections while
and even to persons. shifting the machine.
INSTALLATION AND ADVICE BEFORE USE 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.
GASOLINE ENGINES
+ Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far from
the work area.
1,5
DIESEL ENGINES m
m
1,5
+ Use in open space, air swept or vent exhaust gases
far from the work area. 1,5
m
PUT
UICTO
TCAO
R
DISS
U
GH AA
S
EX
+ Make sure that the machine does not move during the
work: block it possibly with tools and/or devices made
to this purpose.
! ATTENTION
For a safer use from the operator DO NOT
fit the machine in locations with high risk
of flood.
POSITION Please do not use the machine in weather
Place the machine on a level surface at a distance of at conditions which are beyond IP protection
least 1,5 m from buildings or other plants. shown both in the data plate and on page
named "technical data" in this same manual.
10° 10°
= 20° max = 20° max
10° 10°
26/11/99 M2-6GB
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! NOTE
+ Be sure that the lifting devices are: correctly mounted,
adequate for the weight of the machine with it’s pack-
aging, and conforms to local rules and regulations.
When receiving the goods make sure that the product
has not suffered damage during the transport, that
there has not been rough handling or taking away of
parts contained inside the packing or in the set.
In case you find damages, rough handling or absence
of parts (envelopes, manuals, etc.), we advise you to
inform immediately our Technical Service.
2
30/03/00 M3GB
! NOTE
Transportation must always take place with the engine off, electrical cables and starting battery disconnected and
fuel tank empty.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging,
and conform to local rules and regulations.
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.
! NOTE
Transportation must always take place with the engine off, electrical cables and starting battery disconnected and
fuel tank empty.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging,
and conform to local rules and regulations.
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 CTM accessory).
If you did not keep to the instructions, you could damage the structure of the machine.
! 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 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
CTM300 CTL300
! ATTENTION
10/06/00 M6GB
8D
Do not substitute the original tires with other types.
Connect the cable + (positive) Fill the air filter using the same engine oil up to the
to the pole + (positive) of the level indicated on the filter.
battery (after having taken
away the protection), by FUEL
properly tightening the clamp.
Check the state of the battery
from the colour of the warning light which is in the ! ATTENTION
upper part.
Do not smoke or use open flames during
refuelling operations, in order to avoid
- Green colour: battery OK
explosions or fire hazards.
- Black colour: battery to be recharged
Fuel fumes are highly toxic; carry out
- White colour: battery to be replaced
operations outdoors only, or in a well-
DO NOT OPEN THE BATTERY. ventilated environment.
Avoid accidentally spilling fuel. Clean
LUBRICANT any eventual leaks before starting up
RECOMMENDED OIL motor.
MOSA recommends selecting AGIP engine oil.
Refer to the label on the motor for the recommended Refill the tank with good quality diesel fuel, such as
products. automobile type diesel fuel, for example.
Please refer to the motor operating manual for the In rigid environmental temperature conditions, use
recommended viscosity. special winterized diesel fuels or specific additives
in order to avoid the formation of paraffin.
Temperature Time
≤ - 20° C 5 min.
to - 20° C from -10°C 2 min.
to - 10° C from -5°C 1 min.
≥ 5° C 20 sec.
! CAUTION
7. Once the engine has started leave it running at
a reduced speed for some minutes. RUNNING-IN
During the first 50 hours of operation, do not use more
8. Accelerate the engine at max., set lever on ma- than 60% of the maximum output power of the unit and
ximum position and then take up load. check the oil level frequently, in any case please stick
08/04/14 35931-GB
For shutdown under normal conditions, proceed as Turn the key (Q1) to the OFF position.
follows:
1. Position the LOCAL START /REMOTE START
(I6) selector on LOCAL START; (only EAS ver-
sion);
2. cut off power to all utilities by opening the load
switch or opening the thermal-magne-
tic switch (Z2) (input lever in downward
position);
3. Turn and push the accelerator lever (16) in mini-
mum position;
4. allow the motor to run without any load for a few
minutes;
5. turn the key (Q1) to the OFF position.
OFF
ON
START
! WARNING
The start-up selector (I6) LOCAL START / REMO-
TE START enables the start-up and stop controls
for the selected position.
F5
I6
M1
B3
28
O1
GB VERSION
22
N1 16 15 59B 15
26
23-24
O1 Spia lumin. press. olio/oil alert Oil press.warning light/oil alert Voyant lumin. press.huile / oil alert Indic.lum.pres. aceite/oil alert
Q1 Chiave di avviamento Starter key Clé de démarrage Llave de arranque
T7 Strumento analogico V/Hz Analogic instrument V/Hz Instrument analogique Instrumento analógico V/Hz
Z2 Interruttore magnetotermico Thermal-magnetic circ.breaker lnterrupteur magnétothermique Interruptor magnetotérmico
circuit connected. T5.9 T5.10 installation, command, control and signalling operations.
In the case of an intervention Perform connections on the installation in safety
conditions. Position the automatic panel in RESET
T5.3
RESET
T5.5 A M T5.4
tx10 tx1
or LOCKED mode.
RESET I° x1 x0.1I° TEST
x10
1 1.5 0.2 0.3
0.5 2 0.1 0.4
T5.2 T5.1
T5.6 T5.7
ON OFF PRESS TO
RESET
! ATTENTION
Do not keep the central pole on the thermic
protection forcefully pressed to prevent its
intervention.
12/06/03 M37GB_1500G_GE
! MAKE SURE
When the TCM 22-40 is used, it is not possible to connect the E.A.S automatic intervention unit.
The selector LOCAL START/REMOTE START (I6) of the generating set must be switched on REMOTE
START.
07/05/01 M39GB
12/06/03 M40GB_1500G_GE
! WARNING
●● Have qualified personnel do maintenance and troubleshooting work.
●● Stop the engine before doing any work inside the machine. If for any
reason the machine must be operated while working inside, pay at-
tention moving parts, hot parts (exhaust manifold and muffler, etc.)
electrical parts which may be unprotected when the machine is open.
●● Remove guards only when necessary to perform maintenance, and
replace them when the maintenance requiring their removal is complete.
●● Please wear the appropriate clothing and make use of the PPE (Per-
MOVING sonal Protective Equipment), according to the type of intervention HOT surface
PARTS (protective gloves, insulated gloves, glasses). can
●● Do not modify the components if not authorized.
can injure hurt you
- See pag. M1.1 -
! ATTENTION
l Maintenance operations on the electricity-generating group prearranged for automatic operation must be carried
out with the panel in RESET mode.
l Maintenance operations on the installation’s electrical panels must be carried out in complete safety by cutting
off all external power sources: ELECTRICAL POWER, GROUP and BATTERY.
For the electricity-generating groups prearranged for automatic operation, in addition to carrying out all periodic
maintenance operations foreseen for normal usage, various operations must be carried out that are necessary in
relation to the specific type of use. The electricity-generating group in fact must be continuously prepared for operation,
even after prolonged periods of inactivity.
EVERY MONTH
EVERY AND/OR AFTER
EVERY YEAR
WEEK INTERVENTION ON
LOAD
1. TEST or AUTOMATIC TEST cycle to NO-LOAD WITH LOAD
keep the generating set constantly
operative X X
2. Check all levels: engine oil, fuel level,
battery electrolyte,, if necessary top X X
it up.
3. Control of electrical connections and
cleaning of control panel X X
l Carry out motor oil change at least once a year, even if the requested number of hours has not been attained.
05/09/05 M43GB
Start the engine: lt will run until it stops due to the lack
of fuel. ! IMPORTANT
Drain the oil from the engine sump and fill it with new oil In the storage operations avoid that
(see page M25). polluting substances, liquids, exhausted
oils, etc. bring damage to people or
Pour about 10 cc of oil into the spark plug hole and things or can cause negative effects to
screw the spark plug, after having rotated the crankshaft surroindings, health or safety respecting
several times. completely the laws and/or dispositions
in force in the place.
Rotate the crankshaft slowly until you feel a certain com-
pression, then leave it.
Clean the covers and all the other parts of the machine
carefully.
DIESEL ENGINE
Clean the covers and all the other parts of the machine
carefully.
+ Have qualified personnel disassemble the In case of necessity for first aid and fire prevention,
machine and dispose of the parts, including the see page M2.5.
oil, fuel, etc., in a correct manner when it is to
be taken out of service.
! IMPORTANT
As cust off we intend all operations to be made, at In the cust-off operations avoid that
utilizer’s care, at the end of the use of the machine. polluting substances, liquids, exhausted
This comprises the dismantling of the machine, the oils, etc. bring damage to people or
subdivision of the several components for a further things or can cause negative effects to
reutilization or for getting rid of them, the eventual surroindings, health or safety respecting
packing and transportation of the eliminated parts completely the laws and/or dispositions
up to their delivery to the store, or to the bureau in force in the place.
encharged to the cust off or to the storage office, etc.
Y2 : Remote control plug D6 : Connector, PAC G9 : Low water level warning light
A3 : Insulation moitoring E6 : Frequency rpm regulator H9 : Chopper driver PCB
B3 : E.A.S. connector F6 : Arc-Force selector I9 : Fuel filter heater
C3 : E.A.S. PCB G6 : Device starting motor L9 : Air heater
D3 : Booster socket H6 : Fuel electro pump 12V c.c. M9 : ON/OFF switch lamp
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01/03/05 35921
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Tel. + 39 - 0290352.1
Fax + 39 - 0290390466