GE 20 YSX 0313 849209003 - GB USE AND MAINTENANCE MANUAL © MOSA 25/09/12 84920M00 preparato da UPT approvato da DITE
I GB F DESCRIPTION OF THE MACHINE GE 20 YSX M 0 REV.0-09/12 The generating set is a unit which transforms the mechanical energy, generated by endothermic engine, into electric energy, through an alternator. 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 roll-bar for a quick access to the engine and to the air filter.
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.
INDEX M0 M 01 M 1.01 M 1.1 M 1.4 M 1.4.1 M 1.5 ... M 2-2.1... M 2.5 … M 2.6 M 2.7 ... M3 M 4.2 M 6.20 M 20 M 21 M 31 M 32 M 39.12... M 37 -….. M 39.10 M 38.6 M 29.2 M 43 -….. M 40.2 M 45 M 46 M 60 M 61-….. GE 20 YSX 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.
M 1.4 CE MARK REV.5-03/11 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. The indication is shown in a clear, readable and indeleble way on a sticker.
Dichiarazione conformità Declaration of conformity Déclaration de conformité Konformitätserklärung Declaración de conformidad Declaração de conformidade BCS S.p.A. M 1.4.1 REV.0-06/10 Stabilimento di Cusago, 20090 (MI) - Italia V.le Europa 59 Tel.: +39 02 903521 Fax: +39 02 90390466 Sede legale: Via Marradi 1 20123 Milano - Italia DICHIARAZIONE DI CONFORMITA' Déclaration de Conformité – Declaration of Conformity – Konformitätserklärung Conformiteitsverklaring – Declaración de Conformidad BCS S.p.A.
I GB F GE 20 YSX TECHNICAL DATA M 1.5 REV.0-09/12 Technical data GENERATOR Stand-by three-phase power PRP three-phase power PRP single-phase power Frequency Cos ϕ ALTERNATOR Type Insulation class ENGINE Make / Model Type / Cooling system Cylinder / Displacement *Stand by net power **PRP net power Speed Fuel consumption (75% of PRP) Engine oil capacity (max) Starter GENERAL SPECIFICATIONS Tank capacity Running time (75% of PRP) Protection *Dimensions / max.
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.
M 2.6 Installation instructions REV.0-06/10 Installation of a genset has to be planned by qualified and trained technicians, it has to be carried out by a competent organization with qualified personnel and proper equipment. ! ATTENTION Faulty installation can create damage to the genset and the User system, and injury to persons. It is compulsory to install the genset according to the norms in force in the country of installation.
M 2.6.1 Installation instructions REV.0-06/10 Fixed outdoor installation Safe distance ATTENTION ! A safe distance has to be kept between genset and fuel deposits, inflammable goods (cloths, paper, etc.), chemicals, according to indications provided by the authority in charge. In order to avoid potentially dangerous situations, area surrounding genset should be isolated so that unauthorized people will not be able to get close to the unit.
M 2.6.2 Installation instructions REV.0-06/10 Sample of outdoor installation with shelter H=ALTEZZA G.E. H=HEIGTH G.S. H=HAUTEUR G.E. H=ALTEZA G.E. Floor should be levelled and suitable to sustain genset weight. Thresholds on doors and openings should have a barrier in order to avoid liquids leaking.
M 2.6.3 Installation instructions REV.0-06/10 For open gensets installed indoors, we recommend: • The dimensions of the air outlets be such that they have at least the same area of the radiator; • the dimensions of the windows for air outlet is at least on the surface of the radiator.
Luftzirkulation Instalación GE 20 YSX M 2.7 REV.
Abmessungen Dimensiones GE 20 YSX 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.
M 4.2 Transport and handling REV.0-06/10 General precautions when handling the machine. ATTENTION ! When moving/lifting a genset it is imperative to be extremely careful. All moving operations must be carried out be qualified persons. Due to the weight and encumbrance of the genset, an error while moving/lifting the unit may cause serious damage to it or surrounding persons. Moving method The generating sets are lifted with different methods according to the unit’s configuration.
M 4.2.1 Transport and handling REV.0-06/10 Moving the generating set via cables or chains Moving by site trolley / trailer ! Site tow CTL: BEWARE DO NOT TOW the generating set without trailer, be it manually or using a vehicle. Trolleys/trailers should only be used to move the generating set for which they were designed. Road trolley CTV: this trailer is made by the manufacturer and connected to the generating set baseframe, it can not be towed on public roads.
CTL 20 ASSEMBLY M 6.20 REV.0-09/12 ! 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.
M 21 START AND STOP (EP6) REV.0-02/06 Check daily ! NOTE The EAS controls the starting as well as the stop of the engine. Follow attentively the instructions reported in the EAS manual. In these conditions the EP6 has the only function to measure the electric values, hour-meter, etc. Do not alter the primary conditions of regulation and do not touch the sealed parts. The starting of the unit can be effected in 3 different modes: 2) Remote starting with TCM35 Put the “Local/Remote” selector on Local.
M 30 CONTROLS LEGENDE REV.2-07/08 Hydraulic oil level light Welding socket ( + ) Welding socket ( - ) Earth terminal A.C. socket Accelerator lever Feed pump 48V D.C.
Comandi Controls Commandes Mandos GE 20 YSX M 31
Components of frontal panel GE 20 YSX M 32 Z2 Thermal-magnetic circuit breaker General switch for the gen-set. It protects both gen-set and related electrical circuit from over current /short circuit. D Ground fault interrupter (30 mA) Device for protection against not-direct contacts for TN and TT systems (neutral grounded to frame) N2 G.F.I. and circuit breaker General switch for the gen-set. Works as both circuit breaker and G.F.I.
PROTECTIONS M 39.12 EP6 ENGINE PROTECTION REV.1-03/11 4 digits DISPLAY [UP DOWN] Button Ideograms Green LED engine on Button [AUTO] Button [F1] AUTO (Yellow Led) Button [ENTER] (*) Button [+] Key (*) (OFF-ON-START) Button [-] (*) (*) The use of these buttons is reserved only to the manufacturer of the generating set. 1.0 INTRODUCTION The EP6 features Engine and Generating Set control and monitoring.
PROTECTIONS EP6 ENGINE PROTECTION M 39.12.1 REV.1-03/11 [OIL] [ °C ] [O.SPd.] [U.SPd] [bELt] [ALAr] [FUEL](1) [FAIL] [E 04] [E 05](2) [Hi H](2) [Lo H](2) [Hi U] (2) [Lo U](2) [XX.
PROTECTIONS EP6 ENGINE PROTECTION M 39.12.2 REV.0-10/05 Parameter [Default] [P.0] Remote Start Delay Timing (Input #7) [ 1"] Range: 1-59 secs or 1-15 mins Seconds or minutes of continuous REMOTE START command to initiate the automatic engine start (see section 7.0 and [P20] in this section). Remote Stop Delay Timing (Input #7) [ 1"] Range: 1-59 secs or 1-15 mins Seconds or minutes of continuous absence of the REMOTE START command to initiate the stop cycle (see section 7.0 and [P.20] in this section).
PROTECTIONS EP6 ENGINE PROTECTION M 39.12.3 REV.1-03/11 [P.18] [P.19] [P.20] [P.21] [P.22] [P.23] [P.24] [P.25] [P.26] [P.27] [P.28] [P.29] [P.30] [P.31] Alarm Output Timing [ 1'] [inh.] 1-59 secs 1-15 mins and [cont]. Time-out of the alarm output. The code [cont] disables the time-out, and the alarm remains energized until the OFF operating mode is selected. The [inh.] mode enables the use of the external contactor Temperature Switch [n.o.] Selection: [n.o.] or [n.c.] [n.o.
PROTECTIONS EP6 ENGINE PROTECTION M 39.12.4 REV.1-03/11 7.0 REMOTE START The EP6 features REMOTE START only in AUTO operating mode. To operate the REMOTE START, follow the instructions. The EP6 will start the engine after the programmed number of days and the engine will run for the programmed time. To determine how the Automatic Periodic Test is programmed enter the Reading Mode (section 6.0 parameter [P.26] and [P.27]).
M 37 Using the generator REV.3-11/11 It is absolutely forbidden to connect the unit to the public mains and/or another electrical power source . Access forbidden to area adjacent to electricity-generating group for all nonauthorized personnel. ! WARNING For the canopy generator sets provided with doors, the following instruction shall be observed.
M 37.1 Using the generator REV.1-09/05 POWER FACTOR - COS ϕ The power factor is a value which depends on the load’s electrical specifications; it indicates the ratio between the Active Power (kW) and Apparent Power (kVA). The apparent power is the total power necessary for the load, achieved from the sum of the active power supplied by the motor (after the alternator has transformed the mechanical power into electrical power), and the Reactive Power (kVAR) supplied by the alternator.
M 37.2 Using the generator REV.1-09/05 DIFFERENTIAL SWITCH The differential switch or differential relay guarantee protection against indirect contacts due to malfunction currents towards the ground. When the device detects a malfunction current that is higher than the nominal current RESET or the set current, it intervenes by cutting off power to the circuit connected. In the case of an intervention A 1a0 M tx10 1 b 0 tx1 I° x1 x10 1c0 1d0 x0.1I° T5.10 T5.9 T5.3 RESET T5.5 A tx10 1 T5.2 T5.
PROTECTIONS INSULATION MONITORING M 39.10 REV..0-05/01 ! NOTE Don not intervene on the setting of the protection switch. Before using the machine check the ON warning lamp lighting. USE AS TROUBLE INDICATOR: Placed on the front panel, the insulation monitor (A3) is a relay which controls continuously the insulation of the generation a.c. circuits towards the ground. The device generates internally a continuous 12V voltage which is applied between the circuit under control and the ground.
M 38.6 TCM 35 REMOTE CONTROL REV.0-03/06 ! MAKE SURE The selector LOCAL START/REMOTE START (I6) of the generating set must be switched on LOCALSTART. Put the selector „switch board (N7)“ on ON. The coupling of the TCM 35 with the generating set, ready for remot starting, permits to work far from the set itself. The remote control is connected to the front plate (X1), and/or rear plate, with a multiple connector. N.B.
3-WAY VALVE FUEL SYSTEM KIT M 29.2 REV.0-07/10 This system allows to feed the motor of the generator both from its own tank and from an external tank of greater capacity. It consists mainly of two parts: - a three-way valve for the selection of the tank; - two hydraulic type quick disconnect couplings for the connection of the hoses from the external tank.
M 43 MAINTENANCE REV.0-06/10 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.
M 43.1 MAINTENANCE REV.0-09/05 ! l l ATTENTION Maintenance operations on the electricity-generating group prearranged for automatic operation must be carried out with the panel in RESET mode. 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.
Diesel engine Troubleshooting M 40.2 REV.3-07/06 Problem The motor does not start up Possible cause Solution ENGINE 1) Start-up switch (I6) (where it is assembled) in 1) Check position incorrect position 2) Emergency button (L5) pressed 2) Unblock 3) Preheating (where it is assembled) 3) Lacking or insufficient preheating phase for sparkplugs. Malfunction in circuit: repair. 4) Engine control unit or starting key faulty. 4) Replace 5) Battery low 5) Recharge or replace.
Troubleshooting Diesel engine M 40.2.1 REV.4-03/11 Problem Possible cause Solution GENERATOR 1) 2) 1) 2) Voltage switch in position 0 Voltage switch faulty 3) 4) 3) Protection tripped due to overload Differential protection device tripped.
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).
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 60 ELECTRICAL SYSTEM LEGENDE 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 E3 : Alternator : Wire connection unit : Capacitor : G.F.I.
Stromlaufplan Esquema eléctrico GE 15 YSX GE 20 YSX M 61 REV.
Q5 H1 13 27 3 27 3 3 T (I) Z5 + 4 14 P5 26 26 (S) P (I) V5 + OPTIONAL: MG8 L1 4 4 26 - (G) 3 3 Esp. Exp. (2) (1) 15 V8 L5 Data Date Progetto: Project: 05.11.2012 Macchina: Machine: Data: Date: 03.02.2012 84920.S.012-A Balducci F. 4 Approvato: Approved: 3 Dis. Appr. Desi. Appr. Pag.n° di n° Page n° of n° B.F. Disegnatore: Designer: Dis. n°: Dwg. n°: Gauges for water temp. & oil press. kit \ 3 way fuel charge kit 84920.
Schema elettrico Electric diagram Schemas electriques D E NL Stromlaufplan Esquema eléctrico GE 20 YSX M 61.3 REV.
