language USE AND MAINTENANCE MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH CS 230 YSX CC/CV • • • • Motosaldatrice Engine Driven Welder Motosoudeuse Motosoldadoras M A D E • • • • Schweißaggregat Motosoldadora По Вышкам Lassers I N I T A L Y Codice Code Code Codigo Kodezahl Código Код Code C0ME80119003 Edizione Edition Édition Edición Ausgabe Edição Издание Editie 01.
M 0 DESCRIPTION OF THE MACHINE REV.0-01/16 The engine driven welder is a unit which ensures the function as: a) a current source for are welding b) a current source for the auxiliary generation The unit is composed of: a structured base which includes a tank, an engine/alternator unit fixed on the base by 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.
M 1 INDEX REV.
M 1.01 Copyright REV.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.
Notes M 1-1 REV.1-03/14 INFORMATION Dear Customer, We wish to thank you for having bought 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.
M 1.4 CE MARKING REV.7-02/14 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 G P.F.
M 1.5 TECHNICAL DATA REV.0-01/16 GENERATOR Three-phase generation Single-phase generation Single-phase generation Frequency ALTERNATOR Type Insulating class ENGINE Mark / Model Type / Cooling system Cylinders / Displacement Output max Speed Fuel consumption (welding 60%) Engine oil capacity Starter GENERAL SPECIFICATIONS Tank capacity Running time (welding 60%) Protection *Dimensions / max.
M 1.6 TECHNICAL DATA REV.0-01/16 D.C. WELDING Duty cycle Welding current regulation Open circuit voltage C.V. WELDING 210A - 60%, 180 A - 100% 20 - 210 A 65V Welding current Welding voltage regulation 210 A - 60%, 180 A - 100% 14 - 44V STATIC CHARACTERISTIC SIMULTANEOUS UTILIZATION FACTORS WELDING CURRENT 210 A 150 A AUXILIARY POWER 0 kVA 0 kVA 100 A 0 2.7 kVA 6.
M 2 WARNINGS REV.1-02/14 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.
M 2-1 SYMBOLS AND SAFETY PRECAUTIONS REV.2-06/10 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.
PRECAUTION (ENGINE DRIVEN WELDER) M 2-5-1 REV.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.
M 2.6 INSTALLATION AND ADVICE REV.1-06/07 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. 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 DIESEL ENGINES + Use in open space, air swept or vent exhaust gases far from the work area.
Luftzirkulation Instalación Instalação M 2.7 REV.
Abmessungen Dimensiones Dimensões M 2.7.1 REV.
M 3 UNPACKING REV.1-02/04 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.
TRANSPORT AND DISPLACEMENTS COVERED UNITS M 4-1 REV.2-09/11 ! 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.
CTM2 ASSEMBLY M 6.9 REV.0-06/00 ! ATTENTION The CTM 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.
Set-up for operation (Engine diesel) Air cooled systems M 20 REV.2-03/15 BATTERY WITHOUT MAINTENANCE The starter battery is supplied already charged and ready for use. Before starting the gen-set connect the cable + (positive) to the pole + of the battery, by properly tightening the clamp. In case of models with warning light: check the state of the battery by means of the indicator placed in the upper part.
M 21 STARTING - STOPPING THE ENGINE REV.0-01/16 Check daily STOPPING THE ENGINE + Before stopping the engine it is compulsory to effect the following operations: - stop to draw three/single-phase current from the auxiliary sockets NOTE ! Do not alter the primary conditions of regulation and do not touch the sealed parts. STARTING THE ENGINE lnsert the electric protection device (D) lever towards above, see page M37 – OFF - stop to draw power from the welding sockets.
4A 9 10 12 15 16 17 19 22 23 24 24A 24B 25 26 27 28 29 30 31 31A 31B 31C 32 33 34 34A 35 36 37 42 42A 47 49 54 55 55A 56 59 59A 59B 59C 59D 59E 59F 63 66 67A 68 69A 70 71 72 73 74 75 76 79 86 86A 87 88 A3 A4 B2 B3 M 30 CONTROLS LEGENDE REV.3-04/13 Hydraulic oil level light Welding socket ( + ) Welding socket ( - ) Earth terminal A.C. socket Accelerator lever Feed pump 48V D.C.
Comandi Controls Commandes Bedienelemente Mandos Comandos M 31 REV.
USE WELDING ANALOG CONTROL M 33.2 REV.0-01/16 WELDING MODE SELECTION VOLTAGE AND CURRENT REGULATION The Welding Analogue Control unit (WAC) allows two possible control modes: Constant Current (CC) Constant Voltage (CV). The welding option with C.V. characteristic is possible only on those models which support this mode of operation. On such models there is a switch which allows to select the desired mode. The regulation with C.C. characteristic can be used to weld with various types of electrodes.
USE WELDING ANALOG CONTROL M 33.3 REV.0-01/16 CONTACTS A (Ground) ARC FORCE ARC FORCE This type of regulation, possible only in CC mode, it is made via the “arc force” potentiometer located on the WAC panel. For the welding processes which require a constant current the potentiometer must be left in the minimum position. For the welding processes where a certain degree of arc force is suitable, the potentiometer has to be properly adjusted, depending on the electrode type and the welding position.
M 34 USE AS WELDER REV.0-01/16 This symbol (Norm EN 60974-1 security standards for arc welders) signifies that the welder can be used in areas with increased risk of electrical shock. ! ATTENTION The areas, access of which is forbiden to unqualified personel, are: - the control switchboard (front) - the exhaust of the endothermic engine - the welding process. Check at the beginning of any work the electric parameters and/or the control placed on the front.
USE AS A GENERATOR WELDING DIGITAL CONTROL M 37 REV.1-06/10 WARNING It is strictly forbidden to connect the group to the public mains and/or to any other source of electric power. GENERATION IN AC (ALTERNATING CURRENT) Make certain of the efficiency of the ground connection (12). - See page M20 -. Position the GFI switch to ON. + Voltage is now immediately available to the AC sockets. Verify that the voltmeter displays the nominal voltage value (at no load it is close to +10% of the nominal value).
REMOTE CONTROL RC2 RC2/90° ACCESSORY USE (DSP/CS SERIES) M 38.10 REV.3-12/11 PUSH AND SCREW TIGHT PUSH AND SCREW TIGHT The remote control RC, which regulates the welding current in the CC (STICK welding) mode and the welding voltage in the CV (MIG/MAG welding), is connected to the front panel by means of a multipole connector. Adjust the welding current control knob to the correct current for the diameter and type of electrode being welded.
Replace the welding control board ATTENTION For the CS 230 only, there is a risk of failure propagation towards the chopper. Before replacing this board please check that the chopper works properly. If not replace both. P4 Lack of welding Full welding power (without Failure in the control or In order to check the proper operation of these circuits it is necessary to current control current control) regardless drive circuits of the wel- use specific test and troubleshooting tools.
07/02/11 M40CT_GB P10 No welding arc The open circuit voltage is Cable interruption betwezero en the WAC or the welding control board (as applicable depending on the machine type) and the welding sockets P9 Minimum welding The welding current in CC current in CC mode mode with the knob at betoo high ginning of scale is too high and changes when turning the arc force knob (if present, switch in ON position) With the machine stopped, extract the connector plugged to J1 of the WAC / Wel- Fix the cabling or
ASSOCIATED SYMPTOMS POSSIBLE CAUSE WHAT TO DO In order to check the proper operation of the Hall sensor it is necessary to use specific Replace the Hall sensor test and troubleshooting tools. Anyway, a visual inspection coul be enough to localise possible damages, with particular reference to possible wear of the cable end coming out of the Hall sensor potting. Please check also the connector contacts crimping at the opposite end of the cable.
M 43 MAINTENANCE REV.1-01/13 ! MOVING PARTS can injure 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 attention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open.
I GB F M 45 STORAGE REV.0-06/07 In case the machine should not be used for more than 30 days, make sure that the room in which it is stored presents a suitable shelter from heat sources, weather changes or anything which can cause rust, corrosion or damages to the machine. + Have qualified personnel prepare the machine for storage. GASOLINE ENGINE Start the engine: lt will run until it stops due to the lack of fuel. Drain the oil from the engine sump and fill it with new oil (see page M25).
I GB F + M 46 CUST OFF REV.0-06/07 Have qualified personnel disassemble the machine and dispose of the parts, including the oil, fuel, etc., in a correct manner when it is to be taken out of service. As cust off we intend all operations to be made, at utilizer’s care, at the end of the use of the machine.
M 55 RECOMMENDED ELECTRODES (In accordance with A.W.S Standard) REV.0-10/03 The information here below are to be intended only as indicative since the above norm is much larger. For further details please see the specific norms and/or the manufacturers of the product to be used in the welding process. RUTILE ELECTRODES: E 6013 Easily removable fluid slag, suitable foe welding in all position. Rutile electrodes weld in d.c. with both polarities (electrode holder at + or -) and in a.c..
M 60 ELECTRICAL SYSTEM LEGENDE REV.11-06/14 Y1 A2 B2 C2 D2 E2 F2 G2 H2 I2 L2 M2 N2 O2 P2 Q2 R2 S2 T2 U2 V2 Z2 W2 X2 Y2 A3 B3 C3 D3 : Alternator : Wire connection unit : Capacitor : G.F.I.
Stromlaufplan Esquema eléctrique Esquema elétrico M 61.1 REV.
Stromlaufplan Esquema eléctrique Esquema elétrico M 61.2 REV.
Stromlaufplan Esquema eléctrique Esquema elétrico M 61.3 REV.
Stromlaufplan Esquema eléctrique Esquema elétrico M 61.4 REV.
MOSA div. della BCS S.p.A. Viale Europa, 59 20090 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.
