TS 400 PS - BC / PL 50Hz TS 500 PS - BC / PL 60Hz 1013 764409003 - GB USE AND MAINTENANCE MANUAL 19/05/05 76440M00 preparato da UPT approvato da DITE
I GB F DESCRIPTION OF THE MACHINE TS 400 PS TS 500 PS M 0 REV.2-10/13 The TS 400/500 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.
M Quality system 01 REV.4-03/12 UNI EN ISO 9001 : 2008 The certifying institute, ICIM, which is a member ofthe International Certification Network IQNet, awarded the official approval to MOSA after anexamination of its operations at the head office andplant in Cusago (MI), Italy.
TS 400 PS TS 500 PS INDEX M 01 M 1.01 M 1.1 M 1.4 M 1.4.1 M 1.5 M 1.6 M2 M 2.1 M 2.5 M 2.6 M 2.7 M 2.7.1 M3 M4 M 6.3 M 20.... M 21 M 31 M 32 M 34 M 37... M 40... M 43 M 44.1 M 45 M 46 M 55 M 60 M 61-….. M 1 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.0-10/02 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.
I GB F M 1.4 CE MARK REV.6-10/13 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.
I GB F Dichiarazione conformità Declaration of conformity Déclaration de conformité Konformitätserklärung Declaración de conformidad Declaração de conformidade BCS S.p.A. M 1.4.1 REV.2-10/13 Stabilimento di Cusago, 20090 (Mi) - Italia V.le Europa 59 Tel.
I GB F TS 400 PS TS 500 PS TECHNICAL DATA Technical data TS 400 PS A.C. GENERATOR 60 Hz three-phase, asynchronous H Mark / Model PERKINS / 404 D-22G Type / Cooling system Diesel 4-stroke / Liquid Cylinders / Displacement 4 / 2216 cm3 Net output 20.3 kW (27.6 HP) Speed 1500 rpm Fuel consumption (welder 60%) 3.8 l/h Cooling system capacity 7l Engine oil capacity 8.
I GB F D.C. WELDING Welding current electronic regulation (on two scales) Service Striking voltage 100 M 1.6 TS 400 PS TS 500 PS TECHNICAL DATA REV.
M 2 SYMBOLS AND SAFETY PRECAUTIONS REV.0-11/99 - 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.
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.
M 2-5 INSTALLATION AND ADVICE BEFORE USE REV.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. Stop engine when fueling CHECKING BOARD Do not smoke, avoid flames, sparks or electric tools when fueling. ENGINE Unscrew the cap slowly to let out the fuel vapours. Slowly unscrew the cooling liquid tap if the liquid must be topped up.
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 1,5 m DIESEL ENGINES + Use in open space, air swept or vent exhaust gases far from the work area.
Installazione Installation Installation D E NL Luftzirkulation Instalación TS 400 PS TS 500 PS M 2.7 REV.
Dimensioni Dimensions Dimensions D E NL Abmessungen Dimensiones TS 400 PS TS 500 PS M 2.7.1 REV.0-04/05 SILENCED 205 1300 1720 32.5 57.
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.
M 4 TRANSPORT AND DISPLACEMENTS COVERED UNITS REV.1-06/10 ! 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.
M 6.3 CTL22 ASSEMBLY REV.2-05/09 ! 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.
Set-up for operation Water cooled systems M 20 REV.1-09/05 BATTERY WITHOUT MAINTENANCE Connect the cable + (positive) to the pole + (positive) of the battery (after having taken away the protection), by properly tightening the clamp. Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non-filtered air to the inside of the motor.
Set-up for operation Water cooled systems M 20.1 REV.1-02/11 COOLING LIQUID ! ATTENTION Do not remove the radiator tap with the motor in operation or still hot, as the liquid coolant may spurt out and cause serious burns. Remove the tap very carefully. Remove the tap and pour the liquid coolant into the radiator; the quantity and composition of the liquid coolant are indicated in the motor operating manual. Replace the tap, ensuring it is perfectly closed.
STARTING AND STOPPING THE ENGINE M 21 REV.0-05/05 5. start-up at low temperatures. The motor will normally start up without problems down to temperatures of -10° C, -15° C. In case of starting difficulty, it is possible to repeat the starting preheating for a max. time of 10 seconds. For start-up and use at lower temperatures please see the engine manual or turn to our Technical Assistance Center.
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 I GB F D E NL Mandos D N M C2 F5 M1 59A I3 0 0 V 500 1/2 Q1 1 0000101 h 0 V 0 500 W1 ON TELECOMANDO REMOTE CONTROL MAX A 200 A 400A MAX 10 SEC OFF ON N1 OFF ARC FORCE ON TELECOMANDO REMOTE CONTROL FUSE FUSE 1 FUEL 20 400A MAX 10 SEC OFF 1/2 0000101 h FUEL 20 REV.0-04/05 400T230M110M VERSION 400T230M48M VERSION T M 31 TS 400 PS TS 500 PS MAX A 200 A ON OFF ARC FORCE FUSE 48V c.a. 5KVA FUSE 5x20/0.1A 5x20/0.
I GB F FRONT PANEL COMPONENTS 9 c.c. welding sockets (+) Connection 10 c.c. welding sockets (-) sockets for 9 c.c. socket only gouging. welding caOutlet used only for cutting bles. works. T Welding current regulator - allows the regulation of the welding current. ONLY GOUGING 20 TS 400 PS TS 500 PS ON START 59A Motor thermic protection - Protects the battery circuit auxiliary devices: pilot lights, relays, instruments, sensors, etc. from power overloads and short circuits.
USE AS WELDER TS 400 PS TS 500 PS 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 welding sockets, after the machine is started, also with no cables, are anyway under voltage. Check at the beginning of any work the electric parameters and/or the control placed on the front.
I GB F USE AS WELDER TS 400 PS TS 500 PS M 34.1 REV.0-05/05 REDUCTION SCALE 100% A max For small electrodes (up to Ø 3.25-130A and 4-200A) it is recommended to use the reduction scale switch (I3) allowing a more accurate regulation of the welding current (lever position at 130 A and/or 200A). When using electrodes of a diameter greater than 3.25 and/or 4 set the welding scale knob to 100% and/or max. position.
USE AS A GENERATOR TS 400 PS TS 500 PS It is strictly forbidden to connect the group to the public mains a/o to another source of electric power. ! WARNING Sockets are not self-locked: tension is avaible immediately after starting also with no plug. REV.0-05/05 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.
ACCESSORY USE REMOTE CONTROL TC2 / TC2/50 M 38 REV.1-06/05 ON OFF PUSH AND SCREW TIGHT The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector. Position welding current adjusting (T) knob at the necessary current value for the diameter and type of electrode. 09/11/99 M38GB To regulate the current from the TC2 / TC2/50, move the switch (7), located above the multipole connector (8), to "ON" position.
USE OF THE PROTECTION ENGINE PROTECTION ES - EV M 39.4 REV..1-04/03 ENGINE PROTECTION (ES - EV) The devices ES or EV ensure the protection of the engine in case of low oil pressure or engine high temperature.
I GB F TROUBLE SHOOTING Problems TS 400 PS TS 500 PS Possible cause WELDING P1 No welding current but auxiliary 1) Position of remote control switch output is OK 2) Potentiometer defect in welding current control 3) Welding current signal interrupter 4) Defect card 5) Defect in diode bridge M 40 REV.0-05/05 Solution 1) Check that it is in OFF position if there is no remote control, on "0" with remote control inserted. 2) Check the continuity of the welding potentiometer and relative connections.
I GB F TROUBLE SHOOTING Problems TS 400 PS TS 500 PS Possible cause M 40.1 REV.1-06/08 Solution ENGINE P1 The engine does not start or stops 1) Low battery voltage, battery dead 1) Check the warning light “state of the battery”: - Green colour: immediately after startup. or defective. battery OK - Black colour: battery to be recharged - White colour: battery to be replaced - DO NOT OPEN THE BATTERY. 2) Presence of air in the fuel supply 2) Carry out de-aeration on the fuel system.
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 PERIODICAL MAINTENANCE A B C D E F TS 400 PS TS 500 PS M 44.1 REV.
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..
A B C D E F G H I L M N P Q R S T U V Z X W Y A1 B1 C1 D1 E1 F1 G1 H1 I1 L1 M1 N1 O1 P1 Q1 R1 S1 T1 U1 V1 Z1 W1 X1 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 M 60 ELECTRICAL SYSTEM LEGENDE : Alternator : Wire connection unit : Capacitor : G.F.I.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS TS 500 PS M 61.1 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS TS 500 PS 400T230M110M M 61.2 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS 50 Hz 400T230M48M M 61.3 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS-BC TS 500 PS-BC TS 600 PS-BC M 61.4 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS-PL TS 500 PS-PL M 61.5 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS-BC TS 500 PS-BC M 61.6 REV.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico TS 400 PS-PL TS 500 PS-PL M 61.7 REV.
MOSA div. della BCS S.p.A. Stabilimento di Viale Europa, 59 20090 Cusago (MI) Italia Tel. + 39 - 0290352.
