MQ Power DCA220SSJU4F Operation Manual

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Page 1

OPERATION MANUAL

WHISPERWATT™ SERIES

MODEL DCA220SSJU4F

60Hz GENERATOR

(JOHN DEERE 6068HFG09 DIESEL ENGINE)

Revision #3 (02/10/17)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Page 2

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

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DCA220SSJU4F 60 HzGENERATOR

Proposition 65 Warning ........................................... 2

Safety Information .............................................. 5-10

Speciﬁcations ........................................................ 11

Dimensions ............................................................ 12

Installation ........................................................ 13-14

General Information ............................................... 15

General Paralleling Information (Option) .......... 16-18

Major Components ................................................ 19

Engine Controller Unit (ECU 835) ......................... 20

Engine/Generator Control Panel............................ 21

Basler Digital Genset Controller (Option) ......... 22-23

Paralleling Panel (Option) ................................. 24-25

Output Terminal Panel Familiarization .............. 26-28

Load Application .................................................... 29

Generator Outputs ............................................ 30-31

Gauge Reading ..................................................... 31

Output Terminal Panel Connections ................. 32-33

Inspection/Setup ............................................... 34-37

Generator Start-Up Procedure (Manual) .......... 38-39

Generator Start-Up Procedure (Auto Mode) .......... 40

Generator Shut-Down Procedures ........................ 41

Maintenance ..................................................... 42-49

Generator Wiring Diagram ..................................... 50

Generator Wiring Diagram, Basler (Option) ........... 51

Engine Wiring Diagram (ECU 835) ........................ 52

Engine Wiring Diagram

(Basler DGC2020HD Option) ................................ 53

3Ø-480 VAC Parallel Wiring Diagram .................... 55

3Ø-208 VAC Parallel Wiring Diagram .................... 56

Battery Charger Wiring Diagram (Option) ............. 57

Water Heating Element Wiring Diagram (Option) .. 58

Troubleshooting (Generator) .................................. 59

Troubleshooting Diagnostics ................................. 60

Basler DGC-2020 Programming Appendix ...... 61-78

TABLE OF CONTENTS

NOTICE

Speciﬁcations are subject to change without notice.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 3

Page 4

NOTES

PAGE 4 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 5

SAFETY INFORMATION

Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

SAFETY SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with

safety messages.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS INJURY.

or NOTICE.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 5

Page 6

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

lubricate components or attempt service on a

Fix damage to machine and replace any broken parts

store equipment properly when it is not being

used. Equipment should be stored in a clean, dry location

CAUTION

NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not

feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

DANGER

WARNING

NOTICE

This equipment should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modiﬁ cations. Unauthorized equipment modiﬁ cation will void all warranties.

 NEVER disconnect any

devices will void all warranties.

CAUTION

 NEVER

running machine.

NOTICE

 ALWAYS ensure generator is on level ground before use.

 ALWAYS keep the machine in proper running condition.



immediately.

 ALWAYS

out of the reach of children and unauthorized personnel

PAGE 6 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

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ENGINE SAFETY



NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several

State Health Safety Codes and Public Resources Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or ﬂ ames from the engine exhaust. Spark arresters are qualiﬁ ed and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the

SAFETY INFORMATION

DANGER

The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment

requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

DO NOT place hands or fingers inside engine

compartment when engine is running.

NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.



the operating performance.

In order for a diesel engine to operate at peak efﬁ ciency,

to completely burn all of the fuel.

DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

hours to burn off the accumulated unburned fuel.



local Health and Safety Administrator.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 7

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SAFETY INFORMATION

FUEL SAFETY



TOWING SAFETY

 Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer “gross

NEVER

Check the tire air pressure on both towing vehicle and

Trailer tires should be inﬂ ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

backup, brake and trailer lights are connected and

• Secure portable power cables in cable tray with tie

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding, or jack-kniﬁ ng. Smooth, gradual starts and stops will

Trailer should be adjusted to a level position at all times

Raise and lock trailer wheel stand in up position when

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

DANGER

DO NOT start the engine near spilled fuel or combustible

ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

ALWAYS use extreme caution when working with

ﬂ ammable liquids.

DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

CAUTION

Check with your local county or state safety

towing regulations, in addition to meeting

Department of Transportation (DOT) Safety Towing Regulations, before towing

your generator.

Refer to MQ Power trailer manual for additional safety

information.

In order to reduce the possibility of an accident while

transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.

 ALWAYS shutdown engine before transporting

vehicle weight rating.”

 ALWAYS inspect the hitch and coupling for wear.

tow a trailer with defective hitches, couplings, chains, etc.



trailer. Also check the tire tread wear on both vehicles.

 ALWAYS make sure the trailer is equipped with a

chain.

 ALWAYS properly

vehicle.

 ALWAYS

working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



improve towing.

 Avoid sharp turns to prevent rolling.



when towing.



towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

PAGE 8 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

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ELECTRICAL SAFETY

DANGER



Power Cord/Cable Safety

 Make sure power cables are securely connected to the

generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes

Severe injury or death by

can result from operating an ungrounded

drop the battery. There is a possibility that the

keep the battery charged. If the battery is not

recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration

DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

The electrical voltage required to

operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

NEVER insert any objects into the output

receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

SAFETY INFORMATION

generator.

NOTICE

 ALWAYS

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

BATTERY SAFETY

DANGER

 DO NOT

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

DANGER

NEVER let power cords or cables lay in water.

NEVER stand in water while AC power from the

generator is being transferred to a load.

NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 9

WARNING

 ALWAYS wear safety glasses when

handling the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.

 ALWAYS

charged, combustible gas will build up.

 ALWAYS

of combustible gasses.

Page 10

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing



ENVIRONMENTAL SAFETY/

Decommissioning is a controlled process used to safely retire a piece of equipment that is no longer serviceable. If the equipment poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain (beyond life-cycle reliability) and is to be decommissioned (demolition and dismantlement),be sure to follow rules below.

EMISSIONS INFORMATION

The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx)

This engine has been certiﬁ ed to meet US EPA Evaporative

Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the equipment or create an unsafe

Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in ﬁ nes or other penalties.

The emission control label is an integral part of the emission

If a replacement emission label is needed, please contact

immediately with plenty of water.

If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

SAFETY INFORMATION

NOTICE

contained in diesel exhaust emissions.

CAUTION

ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

NOTICE

DECOMMISSIONING

DO NOT pour waste or oil directly onto the ground, down

a drain or into any water source.

Contact your country's Department of

Public Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this equipment.

emissions requirements in the installed conﬁ guration.

condition.

Emission Control Label

system and is strictly controlled by regulations.

The label must remain with the engine for its entire life.

your authorized engine distributor.

When the life cycle of this equipment is over, remove

battery and bring to appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.

When the life cycle of this equipment is over, it is

recommended that the trowel frame and all other metal parts be sent to a recycling center.

Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.

Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.

PAGE 10 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 11

Model

Type

Armature Connection Star with Neutral

Phase

Standby Output

Prime Output

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 240/139

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 480/277

1Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 1Ø 240/120

Power Factor

Frequency

Speed

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Lubricating Type Oil

DEF Tank Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

Includes engine and radiator hoses

Includes ﬁlters

Table 1. Generator Speciﬁcations

DCA220SSJU4F

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

194 kW (242 kVA)

176 kW (220 kVA)

208Y/120, 220Y/127, 240Y/139

416Y/240, 440Y/254, 480Y/277

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

7,695 lbs. (3,490 kg)

8,489 lbs. (3,850 kg)

Table 2. Engine Speciﬁcations

John Deere 6068HF08 Tier 4 Final Certiﬁed

4 cycle, water-cooled, direct injection, turbo-charged

charged air cooled, EGR, DOC, DPF and SCR

4.17 in. x 4.99 in. (106 mm x 127 mm)

415 cu. in. (6.8 liter)

293 HP at 1800 rpm

10.3 gal. (39 liters)

8.18 gal. (31 liters)

API service class CJ-4, John Deere Plus-50

14.5 gal. (55 liters)

#2 Diesel Fuel (Ultra low sulfur diesel fuel only)

69 gal. (260 liters)

12.5 gal. (47.1 L)/hr at full load 9.7 gal. (36.4 L)/hr at 3/4 load

6.9 gal. (26.1 L)/hr at 1/2 load 4.4 gal. (16.7 L)/hr at 1/4 load

SPECIFICATIONS

3Ø

N/A

0.8

60 Hz

1800 rpm

6 cylinders

Electric

12 (150Ah X 1

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 11

Page 12

DIMENSIONS

TOP VIEW

SIDE VIEW

MAXIMUM

LIFTING

POINT

14,050 lbs.

(6,373 kg)

A E

220

FRONT VIEW

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 35.83 in. (910 mm) E 43.70 in. (1,110 mm)

B 35.83 in. (910 mm) F 137.79 in. (3,500 mm)

C 43.70 in. (1,110 mm) G 70.86 in. (1,800 mm)

D 41.34 in. (1,050 mm) H 51.18 in. (1,300 mm)

Dimension in. (mm) Reference Letter Dimension in. (mm)

PAGE 12 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 13

GENERATOR

GROUND LUG

GROUND CABLE

INSTALLATION

GROUND ROD FOR EARTH GROUND. CONNECT TO BUILDING GROUND IF APPLICABLE

REFERENCE

NEC 250-83 (C)

Figure 2. Typical Generator Grounding Application

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 13

Page 14

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

GENERATOR GROUNDING

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground (Figure 2).

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and speciﬁes that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm2)

b. Aluminum - 6 AWG (8.4 mm2)

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set ﬁrmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the ﬂoor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

3. NEC article 250-52(c) speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

NOTICE

This generator has a permanent bonding conductor between the generator stator windings and the frame.

PAGE 14 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 15

GENERAL INFORMATION

GENERATOR

This generator (Figure 4) is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

OPERATING PANEL

The “Operating Panel” is provided with the following:

 ECU 835 Controller (Standard)  Gauge Unit Assembly

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge

• Tachometer

 Panel Light/Panel Light Switch  Hour Check Button  Auto Start/Stop Switch  Emergency Stop Button  Basler DGC2020 Digital Controller (Option)

CONTROL PANEL

The “Control Panel” is provided with the following:

 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltmeter Change-Over Switch  Voltage Regulator  3-Pole, 600 amp Main Circuit Breaker  “Control Box” (located behind Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

• Voltage Change-Over Board

OUTPUT TERMINAL PANEL

The “Output Terminal Panel” is provided with the following:

 Three 120/240V output receptacles (CS-6369), 50A  Three auxiliary circuit breakers, 50A  Two 120V output receptacles (GFCI), 20A  Two GFCI circuit breakers, 20A  Eight output terminal lugs (3Ø power)  Ground Lug  Battery Charger (Optional)  Camloks (Optional)  Jacket Water Heater (Optional)

OPEN DELTA EXCITATION SYSTEM

Each generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectiﬁed and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the conﬁguration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “ﬁxed ceiling” and responds according the demands of the required load.

ENGINE

This generator is powered by a 6 cylinder, 4-cycle water cooled, direct injection, turbocharged, air cooled EGR John

Deere 6068HFG09 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine speciﬁcations.

In keeping with MQ Power’s policy of constantly improving its products, the speciﬁcations quoted herein are subject to change without prior notice.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 7) as a guide for selecting proper extension cable size.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 15

Page 16

GENERAL PARALLELING INFORMATION (OPTION)

PARALLELING

Paralleling is the sharing of a load between two generator sets or more.

LOAD SHARING

Load sharing is deﬁned as the proportional division of the kW and kVAR total load between multiple generator sets in a paralleled system.

Load sharing is essential to avoid overloading and stability problems on the systems’ generator sets.

ACTIVE POWER (KW) LOAD SHARING

When generator sets operate in parallel, the engine speed governor of each generator set determines the proportional sharing of the total active power requirements (kW) of the systems’.

The kW load sharing is achieved by increasing or decreasing fuel to the systems’ engines. As the fuel to the engine of one generator set in a group is increased it will not lead to an increase in speed and hence frequency (as it would if it were operating alone) but it will lead to an increase in the proportion of the total kW load that it will deliver.

As the fuel to the engine of one generator set in a group is decreased it will not lead to a decrease in speed and hence frequency (as it would if it were operating alone) but it will lead to a decrease in the proportion of the total kW load that it will deliver.

The control system of the generator sets (via the engine speed control system) monitors and controls the sharing of the total kW load in proportion to the relative rating of the engines on the systems’ generator sets.

REACTIVE POWER (KVAR) LOAD SHARING

When generator sets operate in parallel the alternator ﬁeld excitation system of each generator set controls the proportional sharing of the total reactive power requirements (kVAR) of the system.

The kVAR load sharing is achieved by increasing or decreasing the ﬁeld excitation to the systems’ alternators

As the ﬁeld excitation of one generator set in a group is decreased i.e. over excited it will not lead to an decrease in voltage (as it would if it were operating alone) but It will lead to an decrease in the proportion of the total kVAR load it will deliver and a increase in its power factor.

An undesirable circulating reactive current (cross current) will ﬂow in the system if the excitation of the alternators are not matched.

ETHERNET COMMUNICATION

Ethernet communication is the preferred method for paralleling. This method supports breaker negotiation to avoid simultaneous breaker closures, kW load sharing and kVAR sharing, soft load transfers on and off loading.

The Ethernet ports are located at the output bus splash panel area. There are two ports which are identical so either one can be used. Using a standard Ethernet cable, interconnect units to be paralleled and or sequenced.

LOAD MANAGEMENT

These generators are set up to automatically manage load, based on demand. Load management is only functional in auto mode. While in auto mode, if the auto start contacts are closed, load management is active by default. Load management will only run the number of units needed to support the load.

If the load demand is small, only one generator will remain running while the other generators will be in standby mode. If the load increases above 80% of its capacity, it will start the next generator. The next generator priority is based on the time remaining on the maintenance timer.

Generators with more time until scheduled maintenance will take priority over units that are almost due for maintenance. Once the second unit starts it will synchronize and parallel in then ramp up to share the load. If the load levels drop below 35% of its combined rating, the generator that is no longer needed will ramp off, shut down and wait in standby mode.

As the ﬁeld excitation of one generator set in a group is increased i.e. over excited it will not lead to an increase in voltage (as it would if it were operating alone) but It will lead to an increase in the proportion of the total kVAR load it will deliver and a decrease in its power factor.

PAGE 16 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 17

GENERAL PARALLELING INFORMATION (OPTION)

SEQUENCING

NOTICE

Ethernet communication is required when the generators are conﬁgured for the sequencing mode of operation.

These generators are capable of sequencing for control of balanced maintenance schedules. As described above, these generators can start and stop as demand raises or lowers. In addition, if the units get to the point of maintenance, it will ramp off and start the next generator to relieve it based on the time remaining on the maintenance timer.

After maintenance is performed, the maintenance timers should be reset to the recommended service interval. This is usually 250 hours depending on the engine oil type.

MAINTENANCE INTERVAL

Maintenance intervals are factory set for 250 hours. The maintenance interval timer will count down to zero indicating that it is time for the unit to be serviced.

Full Password key sequence is ^ Edit ^Edit. The set-point for the desired hours until maintenance can now be changed. Press edit to save.

Pre-alarm Silence allows the user to suppress the toggling of the alarm screen when a new Pre-alarm becomes active. While a Pre-alarm is active, pressing the Alarm Silence button will suppress the fault display.

This happens to be very handy function when the “Maintenance Interval” Pre-Alarm occurs. Right after the Pre-Alarm occurs it will begin toggling between the pre- alarm and the overview screen.

While in this mode, pressing the reset button does not reset the maintenance interval. In order to reset the maintenance interval the overview screen must be selected.

Pressing the alarm silence button will stop the toggling between the pre-alarm and the overview screen.

Once the overview screen is selected, the maintenance interval can be reset by pressing and holding the reset button for 10 seconds.

ANALOG LOAD SHARING

Once the timer counts down to zero, a pre-alarm will appear indicating that the unit is due for maintenance. To reset the maintenance interval back to the default time of 250 hours, press and hold the “Reset” button for ten seconds.

To reset the maintenance interval using the reset button, the Maintenance Due pre-Alarm must be active, and the Basler controller must display the “Overview Screen” (Main Screen).

If the maintenance timer has not yet expired and it is desired to reset the unit back to 250 hours, navigate back to the settings menu. Settings Menu->System Parameters>Engine Statistics->Hours To Maintenance.

When highlighted, press the “Edit” button. Username and Password is required. User Name is A and Password is A. Use the up arrow button () and scroll to the alpha character A, then press edit to select.

Next, the cursor will move to the password ﬁeld, press the up arrow button () and scroll to the alpha character A, then press edit to select.

If no Ethernet cable is available or if paralleling to other equipment with traditional analog load sharing, there is a terminal block to connect a shielded wire pair between the two controls. The voltage ranges are programmable with the default value set by Multiquip at 0-3VDC, which is a common voltage for most controllers.

Please note that when in the load sharing mode the voltage is set to droop at 5%. This setting is programmable, but the default setting is 5%.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 17

Page 18

GENERAL PARALLELING INFORMATION (OPTION)

THREE PHASE 480V/208V PARALLEL WIRING VIA CAMLOCKS

REQUIRED EQUIPMENT

 4/0 Single Conductor Cable (User Supplied)

 CAT5E Shielded Cable or Better (User Supplied)

 Power Distribution Panel (User Supplied)

The following procedure intended to assist the user with the parallel wiring conﬁguration for the DCA220SSJU4F generator using the camlok connector panel.

NOTICE

Only a qualified service technician or licensed electrician with proper training should perform

this installation. Follow all shop safety rules when performing this installation.

PREPARATION

3Ø-208 VAC PARALLEL WIRING CONFIGURATION

1. Using 4/0 cables connect the two generators to the power distribution panel as referenced in the 3Ø-208V parallel wiring diagram.

ETHERNET CABLE CONNECTION

1. Connect a CAT5E Ethernet cable (shielded) between port 1 on both generators as shown in Figure 3.

CAT5E PORT 1

GENERATOR 1

PORT 2

CAT5E ETHERNET CABLE (SHIELDED)

1. Make sure generator is turned off and engine is cool.

2. Disconnect any loads connected to the generator.

3. Place the main circuit breaker in the OFF position.

4. Place the generator in an area free of dirt and debris Make sure it is on secure level ground.

5. Disconnect negative battery cable from the battery.

3Ø-480 VAC PARALLEL WIRING CONFIGURATION

1. Using 4/0 cables connect the two generators to the power distribution panel as referenced in the 3Ø-480V parallel wiring diagram.

DANGER

To prevent arcing make sure cables are securely tighten at power distribution panel, the possibility exist of the unit catching on ﬁre thus causing equipment damage and severe bodily harm.

NOTICE

CAT5E PORT 1

GENERATOR 2

PORT 2

Figure 3. Ethernet Cable Connection

2. Reference Table 4 for additional Ethernet port connections.

Table 4. Ethernet Cable Connections

Generator 1 Generator 2

Port 2 Port 1

Port 1 Port 2

Port 2 Port 2

3. Reconnect battery.

4. Start generator as outlined in start up section of this manual.

When connecting load cables to the power distribution panel be sure to select the correct size of the load cables to handle full load/amperage of both generators (parallel).

PAGE 18 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 19

MAJOR COMPONENTS

220

5 6

GND

Table 5. Generator Major Components

ITEM NO. DESCRIPTION

1 Mufﬂer Assembly

180

140

220

PSI

°F

VOLTS

100

260

DECREASE

INCREASE

OIL PRESS

WATER TEMP

BATTERY

150

120

180

RPMX10

210

FUEL

SPEED

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Screen

Program/

Alarm

Option

Change

Exit

Acknowledge

OFF

V-W

W-U

U-V

OFF

2 Enclosure Assembly

3 Generator Assembly

4 Battery Assembly

5 Engine Assembly

6 Fuel Tank Assembly

Denyo

7 Output Terminal Assembly

8 Circuit Breaker Assembly

9 Auto Start/Stop Controller Assembly

10 Gauge Unit Assembly

11 Operating Panel Assembly

12 Voltage Change-Over Board

Figure 4. Major Components

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 19

Page 20

ENGINE CONTROLLER UNIT (ECU 835)

ECU

Series 800 Controller

Alarm

Screen

Acknowledge

Change

E F

Engine Started

Program

Option

Exit

Shutdown

Pre-Alarm

B C D

Figure 5. Engine Control Unit (ECU)

The deﬁnitions below describe the controls and functions of the Engine Control Unit (Figure 5).

1. ECU 835 Controller — This auto start/stop

controller displays the parameters and the diagnostic troubleshooting messages of the engine, and controls DPF regeneration.

A. ECU Display Screen — Engine fault diagnostic

messages are shown on this LCD display. screen

B. Engine Started Lamp — This lamp when lit

indicates engine is operating normally.

C. Engine Shutdown Lamp — When an engine

failure has occured this lamp will blink. Indicating the engine has been shutdown. The diagnostic fault message will be displayed on the LCD screen.

D. Pre Alarm Lamp — When an engine failure has

occured this lamp will blink. Indicating a pre-fault engine condition and the possibility of engine shutdown.The diagnostic fault message will be displayed on the LCD screen

ECU

PSI

OILPRESS

Alarm

Acknowledge

180

100

Series 800 Controller

Screen Change

140

220

°F

VOLTS

100

260

WATERTEMP

BATTERY

150

120

180

°F

RPMX10

210

FUEL

SPEED

Engine Started

Shutdown

Pre-Alarm

Program

Option

Exit

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

E. Alarm Acknowledge Button — When the engine

experiences a fault, the "Pre Alarm Lamp" or the "Shutdown Lamp" will start blinking. Pushing this button will conﬁrm the fault message and the blinking lamp will change to a solid lamp display. The fault message will be displayed on the screen. When multiple engine faults occur, the lamp will continue blnking until all fault messages are conﬁrmed. The blinking lamp will change to a solid lamp display all current conﬁrmed fault messages will scrool across the screen.

F. Screen Change Button — When this button is

pushed during operation, the screen will cycle through each parameter screen.

G. Option Button — This button is not active. Do

not use.

H. Program/Exit Button — Pushing this button

allows the DPF Force Regen and diagnostic code to be conﬁrmed.

PAGE 20 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 21

PSI

OIL PRESS

ENGINE/GENERATOR CONTROL PANEL

180

ECU

PSI

OILPRESS

Alarm

Acknowledge

100

Series 800 Controller

Screen Change

100

180

140

°F

WATER TEMP

°F

FUEL

220

B C

260

VOLTS

BATTERY

150

120

RPMX10

SPEED

180

210

Figure 6. Gauge Unit Assembly

140

220

°F

VOLTS

100

260

WATERTEMP

BATTERY

150

120

180

°F

RPMX10

210

FUEL

SPEED

Engine Started

Shutdown

Pre-Alarm

Program

Option

Exit

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

The deﬁnitions below describe the controls and functions of the Engine/Generator Control Panel (Figure 6).

1. Gauge Unit Assembly — This assembly houses the

various engine monitoring gauges. These gauges indicate: oil pressure, water temperature, charging voltmeter, fuel and engine speed RPM (tachometer).

A. Oil Pressure Gauge — During normal operation

this gauge be should read approximately 44 psi. (303 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

B. Water Temperature Gauge — During normal

operation this gauge be should read between 185° and 207°F (85°~97°C).

C. Charging Voltmeter Gauge — During normal

operation this gauge indicate minimum 26 VDC

D. Fuel Gauge — Indicates amount of diesel fuel

available.

E. Tachometer — Indicates engine speed in RPM’s

for 60 Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied.

2. Panel Light — For operation at night, panel light

illuminates control panel for ease of reading meters and gauges. Make sure oanel light switch is in the OFF position when light is not in use.

3. Panel Light Switch — When activated will turn on

control panel light.

4. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz

5. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by the ammeter phase-selector switch.

6. AC Voltmeter — Indicates the output voltage present

at the U,V, and W Output Terminal Lugs.

7. Voltage Regulator Control — Allows ±15% manual

adjustment of the generator’s output voltage.

8. Ammeter Change-Over Switch — This switch allows

the AC ammeter to indicate the current ﬂowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

9. Voltmeter Change-Over Switch — This switch allows

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

10. Emergency Stop Switch Button — In the event

of an emergency press this button to shut down the generator.

11. Auto/Start Switch — This switch selects either manual

or automatic operation. Center position is OFF (reset).

12. Hour Check Button — With the engine stopped, press

and hold ths button. The total running hours, fuel level, and battery voltage will be displayed.

13. Voltage Change-Over Board — 6 jumper plates that

allows the generator to be conﬁgured for either 3Ø, 240 or 480 VAC output.

14. Main Circuit Breaker — This three-pole, 600 amp

main breaker is provided to protect the U,V, and W

Output Terminal Lugs from overload.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 21

Page 22

BASLER DIGITAL GENSET CONTROLLER (OPTION)

Figure 7. Basler DGC-2020HD

NOTICE

The Basler DGC-2020HD is an option. It replaces the ECU 835 that comes standard with this generator. For detailed programming information refer to the Basler programming appendix in this manual.

PAGE 22 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 23

BASLER DIGITAL GENSET CONTROLLER (OPTION)

The deﬁnitions below describe the controls and functions of the Digital Genset Controller (Figure 7).

1. LCD Display — Display consists of a LCD color touch

screen. The backlit, 272X480 pixel color LCD serves as the local information source for metering, alarms, pre-alarms, and protective functions. Touch screen capability provides convenient navigation through metering and settings. Display operation is maintained down to –4°F (−20°C).

2. Not In Auto Indicator — This red LED lights when the DGC-2020HD is not operating in AUTO mode.

3. Alarm Indicator — This red LED lights continuously during alarm conditions and ﬂashes during pre-alarm conditions.

4. Supplying Load Indicator — This green LED lights when the generator current is greater than emergency power supply (EPS) threshold current.

5. Programmable Indicators — These three red LEDs light when the corresponding logic element is set true. Logic element PROGLED 1 controls the upper LED, PROGLED 2 controls the middle LED, and PROGLED 3 controls the lower LED. A card is provided for labeling the programmable indicators. See Programmable Indicator Conﬁguration, below.

6. Alarm Silence Pushbutton — Pressing this button tests the DGC-2020HD indicators by exercising all LCD pixels and lighting all LEDs.

7. Lamp Test Pushbutton — Pressing this button tests the DGC-2020HD indicators by exercising all LCD pixels and lighting all LEDs.

8. Auto Pushbutton and Mode Indicator — Pressing the Auto button places the DGC-2020HD in Auto mode. The green Auto mode LED lights when Auto mode is active.

9. Off Pushbutton and Mode Indicator. — Pressing this

button places the DGC-2020HD in Off mode.The red Off mode LED lights when the DGC-2020HD is in Off mode. This button also resets the Breaker Management Pre-Alarms and all MTU ECU Alarms.

10. Run Pushbutton and Mode Indicator. — Pressing

this button places the DGC-2020HD in Run mode. The green Run mode LED lights when Run mode is active.

11. Reset Pushbutton — This button is pressed to cancel

a settings editing session and discard any settings changes. When pressed momentarily, this button resets the Breaker Management Pre-Alarms and all MTU ECU Alarms. This button is also used to reset the Maintenance Interval when pressed for 10 seconds while viewing Hours Until Maintenance or Maintenance Due Pre-Alarm.

12. Arrow Pushbuttons — These four buttons are used

to navigate through the front panel display menus and modify settings.

• The left and right arrow buttons are used to navigate through the menu levels. The right arrow button is pressed to move downward through the menu levels and the left arrow button is pressed to move upward through the menu levels.

• Within a level, the up and down arrow buttons are used to move among items within the menu level. Pressing the down arrow button moves to items lower in the list. Pressing the up arrow button moves to items higher in the list.

• During a settings editing session, the up and down arrow buttons are used to raise and lower the value of the selected setting. The right and left arrow buttons move to different digits.

While in “AUTO” the controller will be in standby awaiting a signal to start via the remote start terminals. While in auto, closure of the auto start contacts will immediately start the engine. Once the generator is up to speed and voltage it will compare its voltage to the bus.

If the bus is dead it will immediately close the contactor to provide power to the load(s). If the bus is already hot from another generator it will ﬁrst synchronize then close its contactor then slowly ramp up to share load if load were present

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 23

13. Edit Pushbutton — Pressing this button starts an

editing session and enables changes to DGC-2020HD settings. At the conclusion of an editing session, the Edit pushbutton is pressed again to save the setting changes.

Page 24

PARALLELING PANEL (OPTION)

Figure 8. Paralleling Panel Components

PAGE 24 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 25

PARALLELING PANEL (OPTION)

The deﬁnitions below describe the controls and functions of the Paralleling Panel (Figure 8).

1. Panel Lights — For operation at night or in dark areas,

panel light illuminates paralleling panel for ease of reading.

2. Panel Light Switch — When activated will turn on

control panel light.

3. Voltage Adjust potentiometer — The voltage adjust

potentiometer is a way to adjust the voltage up or down for ﬁne tuning. The adjustment sends a signal to the controller to offset the system rated voltage (Trim Voltage). It is important that all machines are set to the same value when paralleling.

When ﬁrst turning on the control power, the controller will begin its boot sequence much like a computer does. After completing the boot sequence the unit will be ready to run or be placed in auto for auto start applications.

4. Control Power Toggle Switch — The control power

switch is a master power switch for the digital controller. The control power switch has a latch feature that prevents powering down control power while the engine is running.

For units with manual operated breakers, the breaker will need to be reset by toggling the handle down, then can be turned back to the “ON” position. On models with spring charged breakers resetting the breaker is not necessary.

6. Contactor Operation (Manual Mode) — The For

manual run applications, user action is required to get the generator power to the output bus. Depending on the model, some utilize contactors in series with toggle handle circuit breakers and others have spring charged automatic circuit breakers.

On the spring charged types, the buttons on the breaker itself are not intended for circuit breaker operation. For instructional purposes both will be referred to as “contactor”.

There are two pushbuttons on the control panel for controlling the contactor. There is a green “CLOSE CONTACTOR” button to close the contactor and a red “OPEN CONTACTOR” button to open the contactor. These buttons illuminate to show the contactor status. If the contactor is open, the red “OPEN CONTACTOR” button will be illuminated. If the contactor is closed the green “CLOSE CONTACTOR” button will be illuminated.

5. Emergency Stop Button Switch — The Emergency

Stop pushbutton switch is used to stop the engine in case of emergency or to lock out operation during service. The emergency stop button should not be used for routine stopping of the engine.

Actuation of the Emergency stop button while the control power is on will illuminate the light on the button as well as display “Emergency Stop” on the controller display. Actuating the Emergency stop button will deenergize all controller outputs and cause the engine to stop as well as tripping the circuit breaker. This condition is a latched condition that must be reset prior to restarting the engine.

The procedure for resetting the emergency stop requires several actions. Rotate the emergency stop button to release the spring latch. To clear the latch, the controller must be placed into the off mode by pressing the “OFF” button. While in the “OFF” mode, the “RESET” button must be pressed to clear the E-STOP fault.

These buttons can sometimes be multifunctional depending on the situation. For stand-alone operation the buttons simply close and open the contactor as expected. For paralleling the buttons can act a little different.

When the bus is already hot from another generator, pressing the green online button will initiate a synchronizing sequence before closing the contactor. There will be an image of a synchro scope on the controller display and when the voltage and phases are matched, the contactor will close.

If there was already load on the bus the unit will slowly ramp up load until it is sharing equally with the other generator(s). While sharing load with other generators, pressing the red “OPEN CONTACTOR” button once will initiate a ramp down sequence. The unit will begin to ramp down and when at a low level of load it will automatically open it contactor. Pressing the red “OPEN CONTACTOR” button twice will immediately open the contactor.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 25

Page 26

OUTPUT TERMINAL PANEL FAMILIARIZATION

220

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

NEUTRAL

TERMINAL

GROUND

TERMINAL

HARD WIRE

HOOKUP PANEL

BLACK RED BLUE WHITE GREEN

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 10) shown below is provided for the connection of electrical loads. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel ” (Figure 10) is provided with the following:

 Three (3) 240/139V output receptacles @ 50 amp

 Three (3) Circuit Breakers @ 50 amps

 Two (2) 120V GFCI receptacles @ 20 amp

 Two (2) GFCI Circuit Breakers @ 20 amps

 Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

TWIST-LOCK

CS-6369

AUX. POWER RECEPTACLES

240/139V, 50 AMPS

CIRCUIT BREAKERS FOR CS-6369 TWIST

LOCK RECEPTACLES

120 VAC, 20 AMP

GFCI RECEPTACLES

PAGE 26 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Figure 9. Output Terminal Panel

Page 27

OUTPUT TERMINAL PANEL FAMILIARIZATION

RET

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 10) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the output terminal lugs.

Turn the voltage regulator control knob (Figure 12) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 12. Voltage Regulator Control Knob

Removing the Protective Cover (Hard Wire Hookup Panel)

The output terminal lugs are protected by a protective cover (Figure 13). Un-screw the securing bolts (8) and remove the cover to gain access to the output terminal lugs.

Figure 10. G.F.C.I. Receptacle

Twist Lock Dual Voltage 240/139 VAC Receptacles

There are three 240/139V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 11) provided on the output terminal panel. These receptacles can be accessed in any change-over board conﬁguration.

After the load wires have been securely attached to the output terminal lugs, reinstall the protective cover, and reinstall the retaining bolts

PROTECTIVE

TERMINAL COVER

AINING

BOLT

Figure 13. Protective Terminal Cover

(UVWO Terminal Lugs)

Figure 11. 240/139V Twist-Lock Auxiliary

Receptacles

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 27

Page 28

OUTPUT TERMINAL PANEL FAMILIARIZATION

CS-6369

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 14).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 600A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

TWIST-LOCK

RECEPTACLES

GFCI

RECEPTACLES

BLACK

HARD WIRE

HOOKUP PANEL

BLUE

RED

LOAD

WHITE

GROUND

NEUTRAL

GREEN

LOAD

CAMLOCKS

Over Current Relay

An over current relay (Figure 15) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 15. Over Current Relay

NOTICE

Figure 14. Connecting Loads

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 600 amp main breaker.

To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

PAGE 28 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 29

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 6 below when connecting loads.

Table 6. Power Factor By Load

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

Common power tools 0.8

Table 7. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

1.0

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732

NOTICE

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

 When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

 When connecting a ﬂuorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

 When connecting an electric drill or other power tools,

pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer itch.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 29

Page 30

GENERATOR OUTPUTS

JUMPER

6 PLACES

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage change-over board (Figure 16). To obtain some of the voltages as listed in Table 8 (see below) will require a ﬁne adjustment using the voltage regulator (VR)

control knob located on the control panel.

Voltage Change-Over Board

The voltage change-over board (Figure 16) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection n..

Maximum Amps

Table 9 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.

Table 9. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt 488.9 X 2 amps (4 wire)

1Ø 240 Volt 244.4 amps (4 wire)

3Ø 240 Volt 529 amps

3Ø 480 Volt 264 amps

Figure 16. Voltage Change-Over Board

CAUTION

NEVER attempt to place jumper plates on the voltage change-over board while the generator is in operation. There exist the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even death!

Table 8. Voltages Available

UVWO Output

Terminal Lugs

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

Voltage Change-Over Board

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

PAGE 30 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Voltage Change-Over Board

3-Phase 480/270V Position

Page 31

GENERATOR OUTPUTS/GAUGE READING

JUMPER

6 PLACES

HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

Before taking a reading from either gauge, conﬁgure the Voltage Change-Over Board (Figure 17) which produces the desired output voltage.

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 20) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 21). This process can be repeated for terminals V and W.

Figure 20. AC Ammeter Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 21. AC Ammeter

(Amp reading on U Lug)

Figure 17. Voltage Change-Over Board-

Ø Position

240/3

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 18) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 19).

Figure 18. AC Voltmeter Change-Over Switch

Figure 19. AC Voltmeter Gauge (Volt reading on W-U Lug)

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 31

Page 32

OUTPUT TERMINAL PANEL CONNECTIONS

JUMPER

6 PLACES

BE USED

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the Voltage Change-Over Board and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage change-over board determines the range of the output voltage and can be conﬁgured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V conﬁguration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 22

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required

Figure 24. Voltage Regulator Knob

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 22.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

BLACK

240V

RED

BLUE

240V

WHITE

GREEN

Figure 22. Voltage Change-Over Board

3Ø 240/139V Conﬁguration

2. Connect the load wires to the UVWO terminals as shown in Figure 23

BLACK

Figure 23. UVWO Terminal Lugs

3Ø-240/1Ø-139 Connections

PAGE 32 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

RED

THREE-PHASE

240 VAC (LOAD CONNECTIONS)

BLUE

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

240V

SINGLE-PHASE

240 VAC (LOAD CONNECTIONS)

GROUND

CONNECTION

BE USED

MUST

AT ALL TIMES

Figure 25. UVWO Terminal Lugs

1Ø-240V Connections

1Ø-120V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 22.

2. Adjust voltage regulator knob (Figure 24) for an output of 208V to obtain 120V at the UVWO terminals.

3. Connect the load wires to the UVWO terminals as shown in Figure 26

BLACK

RED

SINGLE-PHASE

BLUE

120V

Figure 26. UVWO Terminal Lugs 1Ø-120V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

Page 33

OUTPUT TERMINAL PANEL CONNECTIONS

BE USED

480 VAC (LOAD CONNECTIONS)

BE USED

277 VAC (LOAD CONNECTIONS)

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exist that could cause a ﬁre.

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation as shown in Figure 27. This conﬁguration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 27.

2. Connect the load wires to the UVWO terminals as shown in Figure 29.

BLACK

RED

480V

THREE-PHASE

BLUE

480V

Figure 29. UVWO Terminal Lugs 1Ø-480V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

1Ø-277V UVWO Terminal Output Voltages

Figure 27. Voltage Change-Over Board

3Ø 480/277V Conﬁguration

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

BLACK

RED

THREE-PHASE

480 VAC (LOAD CONNECTIONS)

BLUE

Figure 28. UVWO Terminal Lugs

3Ø-480V Connection

WHITE

GREEN

GROUND

CONNECTION

BE USED

MUST

AT ALL TIMES

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 27.

2. Connect the load wires to the UVWO terminals as shown in Figure 30.

BLACK

RED

SINGLE-PHASE

BLUE

277V

Figure 30. UVWO Terminal Lugs 1Ø-277V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 33

Page 34

INSPECTION/SETUP

Trailer Fuel Tank

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 600 amp, main circuit breaker is provided to protect the U , V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to itch ALL circuit breakers to the OFF position prior to starting the engine.

LUBRICATION OIL

Fill the engine crankcase with lubricating oil through the ﬁller hole, but DO NOT overﬁll. Make sure the generator is level and verify that the oil level is maintained between the two notches (Figure 31) on the dipstick. See Table 10 for proper selection of engine oil.

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause a ﬁre or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 32). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and reﬁll with the speciﬁed amount of oil as outlined in the John Deere Owner’s Manual. Oil should be warm before draining.

Delo® engine oil is the recommended engine oil for this generator. When replacing engine oil please reﬁll using Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil.

Table 10. Recommended Motor Oil

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after ﬁlling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Generator Internal Fuel Tank

220

Figure 32. Internal Fuel Tank System

PAGE 34 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 35

Refueling Procedure:

Unlevel Ground

WARNING

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks — Make sure fuel cells are level with the

ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 33).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

INSPECTION/SETUP

Figure 35. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

220

300

DO NOT fill on unlevel ground

Level Ground

Figure 33. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel (ultra low sulfur diesel fuel) when refueling.

2. Remove fuel cap and ﬁll tank as shown in Figure 34.

DIESEL

FUEL

Level Ground

FUEL TANK

FILLER POR

Figure 36. Fuel Expansion

DEF Refueling

Diesel exhaust ﬂuid is an aqueous solution made with 32.5% high puirty urea (carbamide) and 67.5 deionized water. DEF is used as a consumable in selective catalytic reduction (SCR) in order to lower NOx concentration from diesel exhaust emissions.

1. Remove the ﬁller cap from the DEF tank (Figure 37),

2. Next add DEF ﬂuid to the tank. DO NOT overﬁll.

DEF TANK

CAP

Figure 34. Fueling the Generator

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 35).

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 35

Figure 37. DEF Tank Filling

Page 36

INSPECTION/SETUP

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

John Deere recommends Cool-Gard II coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the John Deere Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 11 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

antifreeze/summer

Cleaning the Radiator

The engine may overheat if the radiator ﬁns become overloaded with dust or debris. Periodically clean the radiator ﬁns with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect air cleaner in accordance with the John Deere Engine

Owner’s Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to insufﬁcient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the John

Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 38) when depressed with the thumb as shown below.

Table 11. Coolant Capacity

Engine and Radiator 10.3 gal (39 liters)

Reserve Tank N/A

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 12) has been added.

Table 12. Anti-Freeze

Operating Temperatures

Vol %

Anti-Freeze

50 -37 -34

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Freezing Point

°C °F

Figure 38. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

PAGE 36 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 37

INSPECTION/SETUP

BATTERY

This unit is of negative ground DO NOT connect in reverse. Always maintain battery ﬂuid level between the speciﬁed marks. Battery life will be shortened, if the ﬂuid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufﬁciently charged if the speciﬁc gravity of the battery ﬂuid is 1.28 (at 68° F). If the speciﬁc gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the Auto-Off/Reset-Manual itch is in either the AUTO or MANUAL position. ALWAYS make sure that this itch is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 39) are

properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

NEGATIVE

POSITIVE

Figure 39. Battery Connections

ALTERNATOR

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 37

Page 38

GENERATOR START-UP PROCEDURE (MANUAL)

INCORRECT

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 40) in the OFF position prior to starting the engine.

STARTING (MANUAL)

6. Place the Auto-Off/Reset Manual Switch in the

MANUAL position to start the engine (Figure 42).

Figure 42. Auto-Off/Reset Manual Switch

(Manual Position)

NOTICE

If engine fails to start in a speciﬁed number attempts, the shutdown lamp will illuminate and the Auto-Off/ Reset Switch must be placed in the Off/Reset position before the engine can be restarted.

NOTICE

Engine will pre-heat automatically in cold weather conditions." Glow Plug Hold " message will be displayed and the engine will start automatically after pre-heating..

Figure 40. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output terminal lugs as shown in Figure 14. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 41).

CORRECT

7. Once the engine starts, let the engine run for 1-2 minutes Let engine idle longer in cold weather conditions. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem.

8. The generator’s frequency meter (Figure 43) should be displaying the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter

Figure 41. Engine Enclosure Doors

PAGE 38 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 39

GENERATOR START-UP PROCEDURE (MANUAL)

9. The generator’s AC-voltmeter (Figure 44) will display

the generator’s output in VOLTS. If the voltage is not within the speciﬁed tolerance,

Figure 44. Voltmeter

10. Use the voltage adjustment control knob (Figure 45) to increase or decrease the desired voltage.

Figure 45. Voltage Adjust Control Knob

11. The ammeter (Figure 46) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

180

140

100

220

°F

WATER TEMP

260

Figure 48. Coolant Temperature Gauge

14. The tachometer gauge (Figure 49) will indicate the

speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

150

120

RPMX10

SPEED

180

210

Figure 49. Engine Tachometer Gauge

15. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 50).

Figure 46. Ammeter (No Load)

12. The engine oil pressure gauge (Figure 47) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (193~586 kPa).

PSI

OIL PRESS

100

Figure 47. Oil Pressure Gauge

13. The coolant temperature gauge (Figure 48) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 185°~207°F (85°~97°C).

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 39

Figure 50. Main, Aux. and GFCI

Circuit Breakers (ON)

16. Observe the generator’s ammeter (Figure 51) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 51. Ammeter (Load)

17. The generator will run until manually stopped or an abnormal condition occurs.

Page 40

GENERATOR START-UP PROCEDURE (AUTO MODE)

STARTING (AUTO MODE)

DANGER

Before connecting this generator to any building’s electrical system, a licensed

electrician must install an isolation (transfer) switch. Serious damage to

the building’s electrical system may occur without this transfer itch.

CAUTION

When connecting the generator to a isolation (transfer) itch, ALWAYS have power applied to the generator’s internal battery charger. This will ensure that the engine will not fail due to a dead battery.

NOTICE

When the generator is set in the AUTO mode, the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

When starting generator in AUTO mode use the “Manual Start-up” procedure except where noted (see below).

1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure.

2. Place the Auto Off/Reset Manual Switch (Figure 52) in the AUTO position.

Figure 52. Auto Off/Reset Manual Switch (AUTO)

3. Continue operating the generator as outlined in the Manual Start-up procedure (start at step 7).

WARNING

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

NOTICE

When the Auto Off/Reset Manual Switch is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

PAGE 40 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 41

GENERATOR SHUT-DOWN PROCEDURES

MANUAL

(CENTER)

WARNING

NEVER stop the engine suddenly except in an

emergency.

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 53 to the OFF position.

Figure 53. Main, Aux. and GFCI

Circuit Breakers (OFF)

EMERGENCY SHUTDOWN PROCEDURE

1. Place the Auto Off/Reset Manual Switch (Figure 55) in the OFF/RESET position.

AUTO

OFF/RESET

Figure 55. Auto Off/Reset Manual Switch (OFF)

MANUAL

2. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

3. Place the Auto Off/Reset Manual Switch (Figure 54) in the OFF/RESET position.

AUTO

OFF/RESET

Figure 54. Auto Off/Reset Manual itch

(Off/Reset)

4. Verify that all status LEDs on the ECU control panel are OFF (not lit).

5. Remove all loads from the generator.

6. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 41

Page 42

MAINTENANCE

3000 Hrs or Every

36 Months

OTHER

Table 13. Inspection/Maintenance

10 Hrs

DAILY

250 Hrs

500 Hrs

or Every

12 Months

Check Engine Oil and Coolant Levels X

Check Fuel Filter/Water Separator Bowl X

Check Air Cleaner X

Check Air Cleaner Element X

Check for Leaks/Hoses/Clamps X

Check for Loosening of Parts X

Change Engine Oil and Oil Filter *

Clean Unit, Inside and Outside X

Replace Fuel Filter Elements X

Check Engine Mounts X

Service Battery X

Check Air Intake Hoses X

Check Fan Belt Condition X

Engine

Check Automatic Belt Tensioner X

Check Electrical Ground Connection X

Clean Radiator, Check Cooling System X

Coolant Solution Analysis, Add SCA's As Required X

Pressure Test Cooling System X

Check Engine Speed X

Test Thermostats X

Check and Adjust Engine Valve Clearance X

Test Glow Plugs X

Inspect Diesel Particulate Filter (DPF) *

Flush and Reﬁll Cooling System*

2 yrs. or 2000 hrs.

Clean Inside of Fuel Tank 1000 hrs.

Clean DEF Tank As Required

Check Crankcase Ventilation Filter*

Replace Air Cleaner Elements *

Generator

During initial operation of a new engine, change oil and ﬁlter between a minimum of 100 hrs. and a maximum of 500 hrs. Service interval depends

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

1500 hrs.

As Required

on type of oil.

Expectation for minimal service interval will be at least 4500 hrs. based on engine power. However, actual service should take place when

indicated by diagnostic gauge. Please contact nearest authorized Multiquip Service Center for DPF Cleaning.

If John Deere COOL-GARD™ John Deere COOL-GARD™ II is used, the ﬂushing intervals may be extended. See "Testing Diesel Coolant" in

engine manual.

Minimal Service interval will be at least 1500 hrs. or when service indicator light turns on or as indicated by diagnostic guage. Critical emission

related service requred before 1500 hrs. is not necessary. The emissions-related warranty is valid up to 1500 hrs.

Replace primary air ﬁlter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

PAGE 42 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 43

MAINTENANCE

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 13 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 56) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 56) is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 57) wash out any deposits or debris that have accumulated inside the fuel tank.

Figure 56. Air Cleaner/Indicator

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be cleaned or reused..

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 43

Figure 57. Fuel Tank Cleaning

Page 44

MAINTENANCE

SEAL

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — Look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — Inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — Inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel ﬁlter cartridge with new one every 500

hours or so.

 Loosen the drain plug at the lower top of the fuel ﬁlter.

Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

 Vent any air

AIR REMOVAL

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the John Deere Engine Manual for details.

To restart after running out of fuel, turn the itch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Replacing Oil Filter

 Remove the old oil ﬁlter.

 Apply a ﬁlm of oil to the gasket/rubber seal (Figure 58)

on the new oil ﬁlter

OIL

FILTER

Figure 58. Oil Filter

 Install the new oil ﬁlter.

 After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

FLUSHING OUT RADIATOR AND REPLACING COOLANT

 Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overﬂow tank and drain.

 Check hoses for softening and kinks. Check clamps for

signs of leakage.

CHECK OIL LEVEL

Check the crankcase oil level prior to each use, or when the fuel tank is ﬁlled. Insufﬁcient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 31.

PAGE 44 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

 Tighten both cocks and replace the overﬂow tank.

 Replace with coolant as recommended by the engine

manufacturer.

 Close radiator cap tightly.

 Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Page 45

MAINTENANCE

WARNING

Allow engine to cool when ﬂushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

RADIATOR CLEANING

The radiator (Figure 59) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling ﬁns or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the ﬁns and tube.

JACKET WATER HEATER AND INTERNAL BATTERY CHARGER 120 VAC INPUT RECEPTACLES (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 60). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 7).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times.

To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

Figure 59. Radiator Cleaning

GENERATOR STORAGE

For long term storage of the generator the following is recommended:

 Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

 Completely drain the oil from the crankcase and reﬁll if

necessary with fresh oil.

 Clean the entire generator, internal and external.

 Cover the generating set and store in a clean, dry place.

 Disconnect the battery.

 Make sure engine coolant is at proper level.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 45

Figure 60. Battery Charger and Jacket Water

Heater Power Connections

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size.

NOTICE

To ensure adequate starting capability, always have power applied to the generator's internal battery charger..

Page 46

MAINTENANCE

(OUT)

EMISSION CONTROL

The emission control system employed with the John Deere 6068HFG09 diesel engine consist of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). The oxidation catalyst and particulate ﬁlter are housed in one unit (Figure 61).

ENGINE

EXHAUST

DIESEL PARTICULATE

FILTER (DPF)

DIESEL OXIDATION

ENGINE

EXHAUST (IN)

CATALYST (DOC)

Figure 61. Typical DOC/DPF Unit

These devices help in ﬁltering out large amounts of harmful Nitrogen Oxides (NOx) and Particulate Matter (PM) which are emitted by diesel engines. These exhaust emissions pose serious environmental and health risks. It is important to maintain and service this DOC/DPF emission safety device on a periodic basis.

Diesel Oxidation Catalyst (DOC)

 Passive Regeneration — Occurs during normal

operation, typically under heavy load applications. Soot is oxidized faster than it is collected.

 Active Regeneration — Occurs when engine exhaust

temperatures are not high enough to oxidize the soot collected in the DPF. Active regeneration requires assistance from the engine to help increase the heat level in the after-treatment system.

Active regeneration occurs at a normal engine speed of 1800 rpm. In addition active regeneration is initiated automatically by the Engine Control Module (ECM) timer based program every 96 hours. This timer base program will reset at the end of any regeneration mode.

 Forced (Stationary) Regeneration — A forced

regeneration only occurs when the operator has initiated this action at the ECU and the ECM recognizes a preprogrammed set point of soot in the DPF to allow a forced regeneration cycle.

This process can take anywhere from 30 minutes to 1-1/2 hours. When forced regeneration is in process all loads must be removed from the generator, all circuit breakers must be placed in the OFF position (OPEN), and the engine speed set to idle.

DPF PRE-ALARM

In the event the Engine Control Unit (ECU) determines the soot level back pressure and/or tempertaure has reached a pre-determined trip point the ECU will indicate a maintenance action is required by the operator.

The DOC does not ﬁlter particles it oxidizes them. This catalyst (honeycomb like structure) uses a chemical process to break down pollutants in the exhaust stream into less harmful components. In general this catalyst collects/burns accumulated particulates. The DOC contains palladium and platinum which serve as a catalysts to oxidize hydrocarbons and carbon monoxide.

Diesel Particulate Filter (DPF)

A diesel particulate ﬁlter (DPF) is a device designed to remove diesel particulate matter (soot) from the exhaust gas of a diesel engine. This type of ﬁlter usually removes about 85-95% of the soot.

Soot accumulated in the DPF is removed via the "regeneration process". Regeneration is the process of removing the accumulated soot from the ﬁlter. This

regeneration process can occur in a few different ways.

PAGE 46 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

This maintenance action will be shown on the LCD display (DPF Warning Symbol) and the AMBER pre-alarm LED on the ECU control panel will be ON (lit). See Figure 62.

ECU

Series 800 Controller

Engine Started

Alarm

Acknowledge

Screen Change

DPF STAT

Program

Option

Exit

Shutdown

Pre-Alarm

Figure 62. ECU DPF Pre-Alarm

Page 47

MAINTENANCE

The DPF pre-alarm status symbol displayed in Figure 62 indicates the soot level buildup has exceeded a predetermined level and a "Forced Regeneration" action is required.

NOTICE

If the AMBER pre-alarm warning LED is ever ON, the operator should always take immediate action to correct the problem. If the engine is allow to run under this condition, a higher pressure differential will be created in the DPF and will result in the RED status LED being ON, causing an engine shutdown.

ECU

Figure 63. ECU DPF Engine Shutdown

Series 800 Controller

Alarm

Acknowledge

Screen Change

DPF STAT

Program

Option

Engine Started

Shutdown

Pre-Alarm

Exit

FORCED REGENERATION PROCEDURE

Follow the steps below to initiate a forced regeneration:

1. Verify that the AMBER pre-alarm LED is ON or FLASHING and the DPF symbol is shown on the ECU display.

2. Place all circuit breakers in the OFF position.

3. Press the Program/Exit button on the ECU controller and select FORCE REGEN mode.

4. Press and hold the request until the REGEN ACTIVE message is displayed on the screen, then release.

5. Once activated, regeneration will start automatically and the engine speed will increase through the forced regeneration cycle. This process will last anywhere

from 30 minutes to 1-1/2 hours.

NOTICE

During the regeneration cycle the High Exhaust System Temperature (HEST) symbol may be displayed. Display of this symbol can be considered normal during the regeneration period.

If the diesel exhaust ﬂuid (DEF) symbol (Figure 64) is displayed during ECU controller operation, it indicates the following:

NOTICE

If the RED engine shutdown LED is ever ON (Figure 63), John Deere recommends that the DPF be removed, cleaned or replaced. In addition the shutdown code must be cleared. To clear the code, the ECM must be reset by a licensed John Deere Engine Service Technician, using John Deere service software.

NOTICE

Soot and ash will accumulate in the DPF over time and must be cleaned. The ash is a result of the normal oil consumption while the engine is operated. The ash cleaning interval will largely depend on the engine's duty cycle and condition. Normal service intervals for cleaning ash from the DPF is every 6 months (5000 hours).

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 47

 DEF tank level is below 10%. Reference Table 14, DEF

Level System Action System.

 DEF quality is poor. The urea concentration to water is

to high or low.

 Check DEF tank level and check active diagnostics

trouble codes (DTC).

ECU

Figure 64. ECU DEF State Pre-Alarm

Series 800 Controller

Alarm

Screen

Acknowledge

Change

DEF STAT

Program

Option

Engine Started

Shutdown

Pre-Alarm

Exit

Page 48

MAINTENANCE

DEF SEVERE INDUCEMENT ALARMS (DGC2020HD)

If a warning for DEF Severe Inducement is present, consider it just like a “Check Engine Light” the reason for the inducement alarm is available under the menu: Metering>J1939-> Active DTC.

“Def Severe Inducement PA” (PA=Pre-Alarm): This is a notice to the operator to correct the issue before it escalates to an alarm.

Pre-alarm is commonly active when the DEF tank is at a low level, if the tank is reﬁlled the Pre-Alarm is cleared and the unit has no adverse effects.

“DEF Severe Inducement A” (A=Alarm): This is a notice to the operator that an after treatment related DTC is causing the unit to enforce 70% de-rated power and the unit will not be allowed to carry full load. If the load is higher than 30% more than likely the control panel will show an “Under Frequency” (81) warning or alarm.

NOTICE

Unit derate occurs at below 0% DEF level. If DEF level is at empty, engine will shutdown. When reﬁlling with diesel fuel is required, reﬁll DEF tank as well.

NOTICE

DIESEL EXHAUST FLUID (DEF)

The amount of ﬂuid in the DEF tank will be shown on the ECU Controller main screen during operation. The symbol shown in Figure 65 will be shown on the ECU monitor indicating the level of ﬂuid in the DEF tank.

Figure 65. DEF Tank Level Guage

If the engine emissions system malfunction (EESM) symbol (Figure 66) is displayed during ECU controller operation, it indicates the following:

 Engine emissions are outside of normal operation range.

 Sysyem fault has occured.

ECU

Series 800 Controller

EESM

Engine Started

Shutdown

Pre-Alarm

Generator derating occurs during soot levels 4 and 5. Soot level 5 will cause the generator to shutdown If this condition occurs contact your nearest authorized service center.

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

Figure 66. Engine Emissions System

Malfunction Pre-Alarm

Table 14. DEF Level System Action System

DEF Level Over 10% Below 10% 0% Empty or After 4 hrs. From 0%

Controller Message — DEF<10% Tank Level DEF<10% Tank Level DEF Tank Empty Level

DEF Symbol —

Pre-Alarm Lamp — —

Shutdown Lamp — — —

Blinking Blinking

ON ON

Engine Shutdown

PAGE 48 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 49

MAINTENANCE

AUTO REGENERATION PROCEDURE

Auto regeneration process will automatically occur. No operator action is required for this process. Allow the engine to run for at least 30 minutes to complete the automatic regeneration process.

Reference Table 15 for the various soot level stages for the DPF system.

NOTICE

Generator derating occurs during soot levels 4 and 5. Soot level 5 will cause the generator to shutdown If this condition occurs contact your nearest authorized service center.

Table 15. Automatic DPF System

Soot Level 0 Soot Level 1 & 2 Soot Level 3 Soot Level 4 Soot Level 5

Controller Message N/A N/A

DPF Condition

Regen Not

Required

Moderate Soot

Level

NOTICE

DO NOT perform regeneration in conditions where it may be unsafe due to high exhasust temperatures.

NOTICE

The area above and around the generator during the regeneration process should be free of any type of debris, flammable or conbustible materials, as temperatures during the regeneration process can reach as high 1,022 °F (550 °C).

FILTER CLEAN

REQUESTED

High Soot Level

SOOT LEVEL

HIGH!

Very High Soot

Level

SOOT LEVEL

VERY HIGH!

Service DPF

(Soot Only)

Pre-Alarm Lamp N/A N/A Blinking

Shutdown Lamp N/A N/A N/A N/A

REGENERATION (BASLER CONTROLLER)

If a manual regen is needed, the Basler DGC2020 HD controller will announce a pre-alarm on the controller. The pre-alarm will state "NEED MAN REGEN" and "PRESS RUN BUTTON". While in this condition, pressing the RUN button for 5 seconds will initiate the Stationary Forced Regen, it will then display a new pre-alarm "MAN REGEN ACTIVE". Once the regen completes, it will automatically shut down and display "MAN REGEN COMPLT".

DIAGNOSTIC MODE

There is a feature to put the controller in diagnostic mode. Diagnostic mode will keep the key switch on for service tool purposes. To place in diagnostic mode the engine must be in the off mode.

Figure 67. Basler DGC2020 HD Controller

Press the “Alarm Silence” and the “Lamp Test” buttons at the same time for 5 seconds. To exit the diagnostic mode you can press reset, start the engine or turn control power off.

ON ON

Engine

Shutdown

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 49

Page 50

GENERATOR WIRING DIAGRAM

PINK

CONTROL BOX

CONTROL PANEL

COT. B

Voltage Change-Over

Board-240V Set

A J C

CN1

CN2

CN3

CN4

AVR CONNECTOR

(VIEW FROM INSERTING

CIRCUIT

BREAKER

SIDE

(VIEW FROM INSERTING

DKB

2 3 4

2 3

V W

WIRE SIDE)

CB1 CONNECTOR

COT. B

Voltage Change-Over

Board-480V Set

3 2

CONTROL

BOX

SIDE

CONTROL

PANEL

SIDE

(VIEW FROM INSERTING

U2 W2

2 3

1 3

CONNECTOR

WIRE SIDE)

COLOR CODE

B L

WIRE COLOR

BLACK BLUE BROWN GREEN GRAY VIOLET

LB LG

R W Y

WIRE COLOR

RED WHITE YELLOW

LIGHT BLUE LIGHT GREEN

ORANGE

SYMBOL

2 1

Ex Ar Ex Fg

2 3

AVR

CT1~3

CB1

DESIGNATION

ARMATURE WINDING

MAIN GENERATOR FIELD WINDING

EXCITER ARMATURE WINDING

EXCITER FIELD WINDING

AUTOMATIC VOLTAGE REGULATOR

VOLTAGE REGULATING RHEOSTAT

RECTIFIER

CURRENT TRANSFORMER 750/5A

CIRCUIT BREAKER 600 AMPS

OVER CURRENT RELAY

SYMBOL

COT. B

A ~

V ~

CB2~3

CB4~6

CON2~3

CON3~5

DESIGNATION

VOLTAGE CHANGE-OVER BOARD

AMMETER CHANGE-OVER SWITCH

AC AMMETER 0~750, 1,500A

VOLTMETER CHANGE-OVER SWITCH

AC VOLTMETER 0~600V

FREQUENCY METER 45~65 Hz

AUX. CIRCUIT BREAKER 20A

AUX. CIRCUIT BREAKER 50A

RECEPTACLE 520R GFCI 20A, 125V

RECEPTACLE CS-6369 50A, 120/240V

PAGE 50 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 51

GENERATOR WIRING DIAGRAM, BASLER (OPTION)

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 51

Page 52

ENGINE WIRING DIAGRAM (ECU 835)

PAGE 52 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 53

ENGINE WIRING DIAGRAM (BASLER DGC2020HD OPTION)

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 53

Page 54

NOTES

PAGE 54 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 55

(GND.)

O HANDLE FULL

GREEN

(NEU.)

WHITE

(L3)

BLUE

GENERATOR #2

(L2)

RED

3Ø-480 VAC PARALLEL WIRING DIAGRAM

PARALLEL WIRING CONNECTIONS

VIA CAMLOKS DCA220SSJU4F

3-PHASE 480 VAC

(L1)

BLK

(GND.)

GREEN

(NEU.)

WHITE

(L3)

BLUE

GENERATOR #1

(L2)

RED

(L1)

BLK

PHASE C (W)

NOTE:

MINIMUM CABLE SIZE IS 4/0.

ALL FIVE CAMLOK PAIRS ARE BONDED.

POWER DISTRIBUTION PANEL.

POINT OF CONNECTION/COMMON OUTPUT BUS

LOAD/AMPERAGE

LOAD

PHASE B (V)

PHASE A (U)

(528 AMPS @ 480 VAC) OF GENERATOR.

SELECT CORRECT SIZE OF CABLES

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 55

Page 56

GREEN

SELECT

LOAD/AMPERAGE (1200

MAIN CIRCUIT BREAKER ON EACH UNIT

PHASE

WHITE

BLUE

GENERATOR #2

RED

BLK

3Ø-208 VAC PARALLEL WIRING DIAGRAM

PARALLEL WIRING CONNECTIONS

VIA CAMLOKS DCA220SSJU4F

3-PHASE 208 VAC

(GND.)

(NEU.)

(L3)

(L2)

(L1)

GREEN

WHITE

BLUE

GENERATOR #1

RED

BLK

(GND.)

(NEU.)

(L3)

(L2)

(L1)

PHASE C (W)

PHASE B (V)

(GND.)

GREEN

WHITE

(NEUTRAL)

NOTE:

MINIMUM CABLE SIZE IS 4/0.

POWER DISTRIBUTION PANEL.

ALL FIVE CAMLOK PAIRS ARE BONDED.2POINT OF CONNECTION/COMMON OUTPUT BUS

WILL TRIP AT 600 AMPS.

PHASE A (U)

(L3)

BLUE

PHASE C (W)

LOAD

AMPS @ 208 VAC) OF GENERATOR.

(L2)

RED

PAGE 56 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

PHASE B (V)

A (U)

(L1)

BLK

CORRECT SIZE OF CABLES TO HANDLE FULL

Page 57

BATTERY CHARGER WIRING DIAGRAM (OPTION)

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 57

Page 58

WATER HEATING ELEMENT WIRING DIAGRAM (OPTION)

PAGE 58 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 59

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 16 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 16. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check for approximately 19 ohms across J & K on CN1

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 59

Page 60

TROUBLESHOOTING DIAGNOSTICS

HOUR CHECK

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself.

1. With the engine stopped (OFF). Push and hold the

Hour Check Button (Figure 68) located on the control panel.

BUTTON

Figure 68. Hour Check Button

5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode enables the ability to carry out the fault diagnostics as listed below:

 DM1 Active Faults — Displays active fault messages

and codes.

 DM2 Messages and Codes — Displays messages and

codes which previously occurred that are recorded in the Engine Control Module (ECM).

 Last Shutdown — Displays the messages and codes

that caused the most recent shutdown.

6. After perfoming diagnostic tests, place the Auto Off/ Reset Manual Switch in the OFF position

2. While keeping the Hour Check Button pressed, place the Auto Off/Reset Manual Switch (Figure 69) in the MANUAL position.

3. The Hour Check Menu Screen will be displayed on the ECU controller.

4. Releasing the Hour Check Button and pushing the Program/Exit Button on the ECU controller will return the controller to the main screen.

Figure 69. Auto-Off/Reset Switch

(Manual Position)

PAGE 60 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 61

BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Locator

Description

Enter button. This button, found only on the overview screen, enters the Main Menu.

Breaker control. To send an open or close request to a breaker in the system, follow these

Generator metering. Touch the generator in the diagram to view metered voltage, current, frequency, kW, kvar, and power factor values of the local generator.

Touch Screen Operation

DGC-2020HDs with the color touch screen display option (style xTxxxxxxx) provide a convenient means of navigating through menus and settings by allowing direct interaction with what is displayed. All operations that can be performed using the touch screen can also be performed using the pushbuttons. However, critical settings must be initiated using the pushbuttons to prevent accidental operation with the touch screen.

Touch screen controls are illustrated in Figure A. Lett descriptions of Table A.

ered locators in Figure A correspond to the control

Figure A. Touch Screen Controls

Table A. Touch Screen Control Descriptions

steps:

1. Touch the corresponding breaker in the diagram.

2. Press the up or down arrow keys to scroll the options.

3. Press Edit to send the selected breaker command request.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 61

Page 62

BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Locator

Description

Bus metering. Touch a bus in the diagram to view metered voltage, current, frequency, kW, kvar, and power factor values of the corresponding bus in the system.

Mains metering. Touch the mains in the diagram to view metered voltage, current, frequency, kW, kvar, and power factor values of the mains bus.

Back button. Touch the Back button to return to the previous menu.

Menu Option. Touch a menu option to enter its submenu. If the option is an editable value,

adjust it using the arrow pushbuttons, and press the Edit pushbutton to accept the change.

Up and Down Arrows. Touching the Up arrow scrolls the menu options toward the top of the list and touching the Down arrow scrolls the menu options toward the bottom of the list.

Scroll box. This represents the range of options in the list that are currently being displayed. The scroll box has no touch commands.

Scroll bar. Scroll bars represent the entire list of options for the current menu screen.

position in the list.

Disabling the Touch Screen

Touch screen controls may be disabled by way of a setting, front panel pushbuttons, or automatically. A setting is provided on the Front Panel HMI screen to enable or disable the touch screen control. For details, refer to Display Setup, below. To disable touch screen controls using the front panel pushbuttons, press and hold Lamp Test then press Edit. Touch screen controls are disabled automatically if the touch screen detects a press for longer than 60 seconds.

Touching a point in the white portion of the scroll bar will display the menu options at that

Programmable Indicator Configuration

Up to three LED indicators may be programmed to suit the needs of a particular application. A replaceable card (Figure B) is provided that can be labeled to match the function of each programmable indicator.

Figure B. Programmable Indicator Label Card

Information about configuring DGC-2020HD logic to control the programmable indicators can be found in the BESTlogic™Plus chapter.

To label the programmable indicators, perform the following steps.

1. Print the label text on readil

adhesive-backed labels measuring 0.5 by 1.75 inches. Avery part number 18167 is suitable for this purpose.

2. Remove all control power from the DGC-2020HD.

3. Remove the fasteners from the four mounting studs on the DGC-2020HD and separate it from the

mounting panel or optional escutcheon plate. Disconnect the nine terminal block connectors; the Start, Run, and Pre relays; and the Ethernet (copper or fiber), USB, and DB-9 connect

4. Lay the front panel face-down on a suitable work surface.

y-available address label sheets. The label card accommodates

ors.

PAGE 62 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (02/10/17)

Page 63

BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

5. Grasp the tab of the label card and pull free. The label card tab is located on the rear of the DGC-

2020HD, see Figure C . When facing the back of the panel, the label card tab is on the left.

6. Apply the labels created in step 1 to the label cards. The rectangle outlines on the label card

serve as guides for attaching the labels.

7. After applying the new labels, insert the label card into the slot. Ensure that the label card is

oriented properly by viewing the cus

8. Move the DGC-2020HD adjacent to the mounting panel or optional escutcheon plate and

reconnect the cables removed in step 3.

9. Secure the DGC-2020HD to the mounting panel or optional escutcheon plate with the fasteners

removed in step 3. The torque applied to the mounting hardware should not exceed 20 inchpounds or 2.2 newton meters.

10. If desired, verify the function of the programmed indicators before returning

service.

tom labels through the label windows of the front panel.

the DGC-2020HD to

Display Operation and Navigation

The front panel display is used to locally make settings changes and display metering values. Refer to items 11, 12 and 13 in Figure 6 for information on changing settings through the front panel and navigating through the screens.

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 63

Figure C. Label Card Slot Location

Page 64

BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

When attempting to change a protected setting, the DGC-2020HD displays the Login Required screen. To log in, use the up or down arrow keys to scroll through the characters. Use the left or right arrow keys to enter more characters. Once the user name and password have been entered, press the Edit key to log in. To log out, press the Reset key while viewing any screen other than the following screen types:

• Action Event Screen (alarm/pre-alarm screens)

• CS

• Edit Screen

• Pixel Test Screen

• Real Time Clock Screen

• Overview Screen

V Screen

If communication access is active through the modem, USB port, or Ethernet port, the front panel displays “REMOTE COMMS”. If the remote user is logged in to BESTCOMSPlus higher, the front panel can only be used for viewing metering data and settings information. Remote security access must be ended before modifying settings through the front panel.

with Control security access or

Changing a Setting

To change a setting, navigate to the setting and press the Edit key. If you are not already logged in, you will be prompted for your password. Use the up or down arrow keys to raise or lower the value. Use the right or left arrow keys to select different digits. Press the Edit key again when finished.

Sleep Mode

Sleep mode de-energizes the LCD backlight when no pushbutton activity is detected for the duration of the LCD Backlight Timeout delay. Front panel LEDs remain lit during monochrome LCD, the LCD heater is turned off during sleep mode. To enter sleep mode, the DGC2020HD must be operating in OFF mode or Auto mode with the engine not running. Normal display operation resumes when any pushbutton is pressed or the genset is started remotely via the ATS input. Sleep mode is not entered while an alarm is active. Sleep mode can be permanently disabled through BESTCOMSPlus

or the front panel.

sleep mode. In units with the default

Overview Screen

The overview screen is the uppermost screen in the menu structure and is displayed by default. It displays metering information as well as a one-line diagram of the system’s breaker configuration.

System Configuration One-Line Diagram

A one-line diagram of the system breaker configuration is displayed on the front panel. This diagram changes in real time to reflect the current state of the breakers.

The one-line diagram appears on both the front panel Overview and Summary screens. Figure D, illustrates the different configurations of the one-line diagram.

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

G SYS

Tie Breaker and Tie Breaker

Generator Breaker and Tie Breaker

SYS

Tie Breaker

Generator Breaker, Group Breaker, and System Bus

Generator Breaker and System Bus

Generator Breaker, Group Breaker, and Mains Breaker

Generator Breaker and Group Breaker

Generator Breaker and Mains Breakers

G L

P0071-90

The diagrams in Figure D show all breakers in the open position and all buses in a dead/unstable state. Breaker and bus states in the diagram When a breaker is open, the line between the contacts is vertical and when the breaker is closed, the line is horizontal. A stable bus is indicated by a filled rectangle and a bus in any state other than stable is indicated by an unfilled rectangle. On the optional touch screen, a dead bus is indicated by a green colored line segment and an energized (failed or stable) is indicated by Figure E for the different breaker and bus states.

Figure D. System Configuration One-Line Diagrams

Generator Breaker

None

change in real time to reflect the actual breaker and bus status.

a red colored line segment. See

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 65

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Both buses dead/unstable

One bus stable and the other dead/unstable

Both buses stable

Breaker Closed

Breaker Open and OK to Close

Breaker Open and Not OK to Close

Breaker Open and Close Request Sent

Breaker Closed and Open Request Sent

Breaker Open and Failed to Close

P0071-91

Breaker Closed and Failed to Open

Figure E. One-Line Diagram Breaker and Bus States

Front Panel Shortcuts

Front panel shortcuts allow the user to intuitively view metered bus values and issue breaker commands by simply selecting components in the one-line diagram.

While viewing the overview screen, press Edit to enable a cursor in the system configuration one-line diagram. Moving the cursor, by using the left and right arrow keys, selects different components in the system diagram. A component selected by the cursor is displayed with inverted colors to diffe from the rest.

Select a bus in the diagram with the cursor and press Edit to view metered voltage, current, frequency, kW, kvar, and power factor values of the corresponding bus in the system.

To send an open or close request to a breaker in the system, move the cursor to the corresponding breaker in the diagram and press Edit. Press the up or down arrow keys to scroll the options. Press Edit again to send the selected breaker command request.

The system conf the System Type setting selection. For details on configuring the system type, see the Configuration chapter.

Scrolled Metering

BESTCOMSPlus®Navigation Path: Settings Explorer, General Settings, Front Panel HMI Front Panel Navigation Path: Settings > General Settings > Front Panel HMI

When scrolled metering is enabled, user-selected metering values are displayed on the overview screen. Any number of the available values can be displayed. Up to nine values are displayed on the screen at one time. After the scroll time delay has elapsed, the next set of values is displayed and so on.

When scrolled metering

• VOLT∗

• AMP∗

• PH∗

• Hz

• OIL

iguration one-line diagram which is displayed on the overview screen is determined by

is disabled, only the following parameters are displayed on the overview screen:

rentiate it

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

• FUEL/DEF†

• TEMP/RUN HRS

• BATT/RUN HRS

∗ When scrolled metering is disabled, individual phase information can be automatically toggled at a rate

set by the Phase Toggle Delay setting on the Front Panel HMI screen. When the Phase Toggle Delay is set to zero, information for each phase is obtained by pressing the up or down arrow keys on the front panel. When it is set to a number other than zero, the display will toggle through the phases automatically at the rate specified by t

he Phase Toggle Delay Setting. The overview screen automatically alternates the

display of TEMP/BATT and RUN HRS.

† When a Selective Catalytic Reduction (SCR) with Diesel Exhaust Fluid (DEF) exhaust after-treatment system is implemented, the overview screen automatically alternates the display of FUEL level and DEF level.

To select the scrolling values, navigate to the Settings, General Settings, Front Panel HMI screen and edit the Scrolled Item Selection. The following paramet

ers may be placed in the scrolling overview:

Adjusted Reserve Available Analog Expansion Module 1: Inputs: AEM1 In1 Analog Expansion Module 1: Inputs: AEM1 In2 Analog Expansion Module 1: Inputs: AEM1 In3 Analog Expansion Module 1: Inputs: AEM1 In4 Analog Expansion Module 1: Inputs: AEM1 In5 Analog Expansion Module 1: Inputs: AEM1 In6 Analog Expansion Module 1: Inputs: AEM1 In7 Analog Expansion Module 1: Inputs: AEM1 In8 Analog Expansion Module 1: Resistance

Temperature

Detectors (RTD): AEM1 RTD1

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD2

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD3

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD4

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD5

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD6

Analog Expansion Module 1: Resistance Temperature Detectors (

RTD): AEM1 RTD7

Analog Expansion Module 1: Resistance Temperature Detectors (RTD): AEM1 RTD8

Analog Expansion Module 1: Thermocouples: AEM1 TC1

Analog Expansion Module 1: Thermocouples: AEM1 TC2

Analog Expansion Module 2: Inputs: AEM2 In1 Analog Expansion Module 2: Inputs: AEM2 In2 Analog Expansion Module 2: Inputs: AEM2 In3 Analog Expansion Module 2: Inputs: AEM2 In4 Analog Expansion Module 2: Inputs: AEM2 In5 Analog Expansion Module 2: Inputs: AEM2 In6 Analog Expansion

Module 2: Inputs: AEM2 In7

Analog Expansion Module 2: Inputs: AEM2 In8

Analog Expansion Module 2: Resistance Temperature Detectors (RTD): AEM2 RTD1

Analog Expansion Module 2: Resistance Temperature Detectors (RTD): AEM2 RTD2

Analog Expansion Module 2: Resistance Temperature Detectors (RTD): AEM2 RTD3

Analog Expansion Module 2: Resistance Temperature Detectors (RTD): AEM2 RTD4

Analog Expansion Module 2: Resistance Temperature Detectors (RTD): AEM2 RTD5

Analog Expansion M

odule 2: Resistance

Temperature Detectors (RTD): AEM2 RTD6 Analog Expansion Module 2: Resistance

Temperature Detectors (RTD): AEM2 RTD7 Analog Expansion Module 2: Resistance

Temperature Detectors (RTD): AEM2 RTD8 Analog Expansion Module 2: Thermocouples:

AEM2 TC1 Analog Expansion Module 2: Thermocouples:

AEM2 TC2 Analog Expansion Module 3: Inputs: AEM3 In1 Analog Expansion Module 3: Inputs: AEM3 In2 Analog Expansion Module 3: Inputs: AEM3 In3 Analog Expansion Module 3: I

nputs: AEM3 In4 Analog Expansion Module 3: Inputs: AEM3 In5 Analog Expansion Module 3: Inputs: AEM3 In6 Analog Expansion Module 3: Inputs: AEM3 In7 Analog Expansion Module 3: Inputs: AEM3 In8 Analog Expansion Module 3: Resistance

Temperature Detectors (RTD): AEM3 RTD1 Analog Expansion Module 3: Resistance

Temperature Detectors (RTD): AEM3 RTD2 Analog Expansion Module 3: Resistance

Temperature Detectors (RTD): AEM3 RTD3 Analog Expansion Module 3: Resistance

Temperature Det

ectors (RTD): AEM3 RTD4

Analog Expansion Module 3: Resistance Temperature Detectors (RTD): AEM3 RTD5

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 67

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Analog Expansion Module 3: Resistance Temperature Detectors (RTD): AEM3 RTD6

Analog Expansion Module 3: Resistance Temperature Detectors (RTD): AEM3 RTD7

Analog Expansion Module 3: Resistance Temperature Detectors (RTD): AEM3 RTD8

Analog Expansion Module 3: Thermocouples: AEM3 TC1

Analog Expansion Module 3: Thermocouples: AEM3 TC2

Analog Expansion Module 4: Inputs: AEM4 In1 Analog Expansion Module 4: Inputs: AEM4 In2 Analog Expansion Module 4: Inputs: AEM4 In3 Analog E

xpansion Module 4: Inputs: AEM4 In4 Analog Expansion Module 4: Inputs: AEM4 In5 Analog Expansion Module 4: Inputs: AEM4 In6 Analog Expansion Module 4: Inputs: AEM4 In7 Analog Expansion Module 4: Inputs: AEM4 In8 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD1 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD2 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD3 Analog Expansion Module 4: Resistan

Temperature Detectors (RTD): AEM4 RTD4 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD5 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD6 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD7 Analog Expansion Module 4: Resistance

Temperature Detectors (RTD): AEM4 RTD8 Analog Expansion Module 4: Thermocouples:

AEM4 TC1 Analog Expansion Module 4: Thermocouples:

AEM4 TC2 Analog Inputs: Anal

og In 1 Analog Inputs: Analog In 2 Analog Inputs: Analog In 3 Analog Inputs: Analog In 4 Analog Outputs: AVR Output Analog Outputs: GOV Output Analog Outputs: LS Output Base Load Level Battery Voltage Boost Pressure Bus 1 Current: 3i0 Bus 1 Current: Average Bus 1 Current: I1 Bus 1 Current: I2

Bus 1 Current: Phase A Current Bus 1 Current: Phase B Current Bus 1 Current: Phase C Current Bus 1 Current: Ground Bus 1 Dead Bus 1 Failed Bus 1 Forward Rotation Bus 1 Frequency: Fr

equency Bus 1 Frequency: Max ROCOF Bus 1 Frequency: ROCOF Bus 1 Power: Max Vector Shift Bus 1 Power: Negative Var Hours Total Bus 1 Power: Negative Watt Hours Total Bus 1 Power: Phase A Complex Power Bus 1 Power: Phase A Power Factor Bus 1 Power: Phase A Vars Bus 1 Power: Phase A Watts Bus 1 Power: Phase B Complex Power Bus 1 Power: Phase B Power Factor Bus 1 Power: Phase B Vars Bus 1 Power: Phase B Watts Bus 1 Power: Phase C Complex Power Bus 1 Power: Phase C P

ower Factor Bus 1 Power: Phase C Vars Bus 1 Power: Phase C Watts Bus 1 Power: Positive Var Hours Total Bus 1 Power: Positive Watt Hours Total Bus 1 Power: Power Factor Lead/Lag Bus 1 Power: Total Complex Power Bus 1 Power: Total Power Factor Bus 1 Power: Total Vars Bus 1 Power: Total Watts Bus 1 Power: Volt-Ampere Hours Total Bus 1 Reverse Rotation Bus 1 Stable Bus 1 Voltage: Average Voltage L-L Bus 1 Voltage: Average Voltage L-N Bus 1 Vo

ltage: Connection Bus 1 Voltage: V2 Bus 1 Voltage: Voltage Phase A Bus 1 Voltage: Voltage Phase A To Phase B Bus 1 Voltage: Voltage Phase B Bus 1 Voltage: Voltage Phase B To Phase C Bus 1 Voltage: Voltage Phase C Bus 1 Voltage: Voltage Phase C To Phase A Bus 2 Current: 3i0 Bus 2 Current: Average Bus 2 Current: I1 Bus 2 Current: I2 Bus 2 Current: Phase A Current

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Bus 2 Current: Phase B Current Bus 2 Current: Phase C Current Bus 2 Current: Ground Bus 2 Dead Bus 2 Failed Bus 2 Forward Rotation Bus 2 Frequency: Frequency Bus 2 Frequency: Max ROCOF Bus 2 Frequency: ROCOF Bus 2 Power: Max Vector Shift Bus 2 Power: Negative Var Hours Total Bus 2 Power: Negative Watt Hours Total Bus 2 Power: Phase A Complex Power Bus 2 Power: Phase A Power Factor Bus 2 Power: Phase A Vars Bus 2 Power: Phase A Watts Bus 2 Power: Phase B Complex Power

Power: Phase B Power Factor

Bus 2 Bus 2 Power: Phase B Vars Bus 2 Power: Phase B Watts Bus 2 Power: Phase C Complex Power Bus 2 Power: Phase C Power Factor Bus 2 Power: Phase C Vars Bus 2 Power: Phase C Watts Bus 2 Power: Positive Var Hours Total Bus 2 Power: Positive Watt Hours Total Bus 2 Power: Power Factor Lead/Lag Bus 2 Power: Total Complex Power Bus 2 Power: Total Power Factor Bus 2 Power: Total Vars Bus 2 Power: Total Watts Bus 2 Power: VoltBus 2 Reverse Rotation Bus 2 Stable Bus 2 Voltage: Average Voltage L-L Bus 2 Voltage: Average Voltage L-N Bus 2 Voltage: Connection Bus 2 Voltage: V2 Bus 2 Voltage: Voltage Phase A Bus 2 Voltage: Voltage Phase A To Phase B Bus 2 Voltage: Voltage Phase B Bus 2 Voltage: Voltage Phase B To Phase C Bus 2 Voltage: Voltage Phase C Bus 2 Voltage: Voltage Phase C To Phase A Charge Air Temperature Contact Expansion Module 1: CEM1 Inpu Contact Expansion Module 1: CEM1 Input 2 Contact Expansion Module 1: CEM1 Input 3 Contact Expansion Module 1: CEM1 Input 4 Contact Expansion Module 1: CEM1 Input 5

Ampere Hours Total

t 1

Contact Expansion Module 1: CEM1 Input 6 Contact Expansion Module 1: CEM1 Input 7 Contact Expansion Module 1: CEM1 Input 8 Contact Expansion Module 1: CEM1 Input 9 Contact Expansion Module 1: CEM1 Input 10 Contact Expansion Module 2: CEM2 Input 1 Contact Expansion Module 2: CEM2 Input 2 Contact Expansion Module 2 Contact Expansion Module 2: CEM2 Input 4 Contact Expansion Module 2: CEM2 Input 5 Contact Expansion Module 2: CEM2 Input 6 Contact Expansion Module 2: CEM2 Input 7 Contact Expansion Module 2: CEM2 Input 8 Contact Expansion Module 2: CEM2 Input 9 Contact Expansion Module 2: CEM2 Input 10 Contact Expansion Module 3: CEM3 Input 1 Contact Expansion Module 3: CEM3 Input 2 Contact Expansion Module 3: CEM3 Input 3 Contact Expansion Module 3: CEM3 Input 4 Contact Expansion Contact Expansion Module 3: CEM3 Input 6 Contact Expansion Module 3: CEM3 Input 7 Contact Expansion Module 3: CEM3 Input 8 Contact Expansion Module 3: CEM3 Input 9 Contact Expansion Module 3: CEM3 Input 10 Contact Expansion Module 4: CEM4 Input 1 Contact Expansion Module 4: CEM4 Input 2 Contact Expansion Module 4: CEM4 Input 3 Contact Expansion Module 4: CEM4 Input 4 Contact Expansion Module 4: CEM4 Input 5 Contact Expansion Module 4: CEM4 Input 6 Contact Ex Contact Expansion Module 4: CEM4 Input 8 Contact Expansion Module 4: CEM4 Input 9 Contact Expansion Module 4: CEM4 Input 10 Contact Inputs: Input 1 Contact Inputs: Input 2 Contact Inputs: Input 3 Contact Inputs: Input 4 Contact Inputs: Input 5 Contact Inputs: Input 6 Contact Inputs: Input 7 Contact Inputs: Input 8 Contact Inputs: Input 9 Contact Inputs: Input 10 Contact Inputs: Input 11 Contact Inputs: Input 12 Contact Inputs: Input 13 Contact Inputs: Input 14 Contact I

pansion Module 4: CEM4 Input 7

nputs: Input 15

Module 3: CEM3 Input 5

: CEM2 Input 3

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 69

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Contact Inputs: Input 16 Contact Outputs: Output 1 Contact Outputs: Output 2 Contact Outputs: Output 3 Contact Outputs: Output 4 Contact Outputs: Output 5 Contact Outputs: Output 6 Contact Outputs: Output 7 Contact Outputs: Output 8 Contact Outputs: Output 9 Contact Outputs: Output 10 Contact Outputs: Output 11 Contact Outputs: Output 12 Contact Outputs: Prestart Contact Outputs: Run Contact Outputs: Start Coolant Level Settings Coolant Pressure Coolant Temperature Device ID Diesel Exhaust Fuel Tank Lev Diesel Exhaust Fuel Tank Level 2 Differential: Iop 2nd A Differential: Iop 2nd B Differential: Iop 2nd C Differential: Iop 5th A Differential: Iop 5th B Differential: Iop 5th C Differential: Iop A Differential: Iop B Differential: Iop C Differential: Iop N Differential: Ir A Differential: Ir B Differential: Ir C DPF Outlet Gas Temperature Engine Intercooler Temperature Engine Load Engine Oil Temperature Engine Percent Load Engine Speed (Rpm) Fuel Level Fuel Pressure Fuel

Rate Fuel Temperature Gen Current: 3i0 Gen Current: Average Gen Current: Ground Current Gen Current: I1 Gen Current: I2

el 1

Gen Current: Phase A Current Gen Current: Phase B Current Gen Current: Phase C Current Gen Current: Ground Gen Dead Gen Failed Gen Forward Rotation Gen Frequency: Frequency Gen Frequency: Max ROCOF Gen Frequency: ROCOF Gen Power: Max Vector Shift Gen Power: Negative Var Hours Total Gen Power: Negative Watt Hours Total Gen Power: Phase A Complex Power Gen Power: Phase A Power Factor Gen Power:

Gen Power: Phase A Watts

Gen Power: Phase B Complex Power

Gen Power: Phase B Power Factor

Gen Power: Phase B Vars

Gen Power: Phase B Watts

Gen Power: Phase C Complex Power

Gen Power: Phase C Power Factor

Gen Power: Phase C Vars

Gen Power: Phase C Watts

Gen Power: Positive Var Hours Total

Gen Power: Positive Watt Hours Total

Gen Power: Power Factor Lead/Lag

Gen Power: Total Complex Power

Gen Power: Total Power Factor

Gen Power: Total Vars

Gen Power:

Gen Power: Volt-Ampere Hours Total

Gen Reverse Rotation

Gen Stable

Gen Voltage: Average Voltage L-L

Gen Voltage: Average Voltage L-N

Gen Voltage: Connection

Gen Voltage: V2

Gen Voltage: Voltage Phase A

Gen Voltage: Voltage Phase A To Phase B

Gen Voltage: Voltage Phase B

Gen Voltage: Voltage Phase B To Phase C

Gen Voltage: Voltage Phase C

Gen Voltage: Voltage Phase C To Phase A

Generated kvar

Generated kW

Injector Metering Rail Pressure

Intake Manifold Temperature kvar Error

Phase A Vars

Total Watts

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kvar PID kvar Ramp Status kvar Setpoint kW Error kW Load Percent kW PID kW Ramp Status Load Share Active Logic Control Relays: LCR 1-64 LS Input Mains Base Load Mains Total System kW Load Next To Start Next To Stop Number of Units Number of Units in Active Segment Number of Units Online Oil Pressure PF Mode PF Setpoint Ramped Var Demand Ramped Watt Demand Rated kvar Rated kW Real Time Clock: Date Real Time Clock: Time Reserve Available Speed Bias Output Speed Error Speed PID Speed Source S

ystem Load Bus: Frequency

System Load Bus: Total PF System Load Bus: Total var System Load Bus: Total Watt System Load Bus: Average Current System Load Bus: Average Voltage System Generated kvar System Generated kW System Generated kW Percent System Group Bus: Frequency System Group Bus: Total PF System Group Bus: Total var System Group Bus: Total Watt System Group Bus: Average Current System Group Bus: Average Voltage System Mains Bus: Frequency System Mains Bus: Total System Mains Bus: Total var System Mains Bus: Total Watt System Mains Bus: Average Current System Mains Bus: Average Voltage System Manager System Online kvar Capacity System Online kW Capacity System Total kW Capacity Total Fuel Used Total Run Time Var Demand Var Mode Volt Error Volt PID Voltage Bias Output Watt Demand

Main Menu

Pressing the right arrow key while viewing the Overview screen opens the Main Menu screen. The Main Menu screen options consist of Metering, Sett specific metering information. Settings screens primarily contain settings for configuring the DGC-2020HD. The Summary screen consists of a one-line diagram of the system configuration, mains fail transfer status, bus metering, and breaker command options.

Summary Screen

A one-line diagram, located at the top of the Summary screen, indicates system configuration and real time breaker status. This one-line diagram is essentially the same as the one described in Overview Screen above, except this diagram does not contain the shortcuts.

Mains fail transfer status is displayed just below the diagram. Mains fail transfer timers can be viewed by selecting Mains fail transfer status (top line) and pressing the right arrow key. Press the left arro return to the Summary screen. See Metering chapter for details.

Metering of voltage, current, frequency, power, and power factor for the generator bus is displayed. Only metered voltage and frequency for Bus 1 and Bus 2 are displayed.

Breakers in the system are listed at the bottom of the Summary screen. To send an open or close request to a breaker in the system, move the cursor to the desired breaker in the list and press Edit. Press the up

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 71

ings, and Summary. Metering screens primarily display

w key to

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

or down arrow keys to scroll the options. Press Edit again to send the selected breaker command request. Breaker abbreviations are defined below:

GB = Generator Breaker

•

GGB = Generator Group Breaker

•

MB = Mains Breaker

•

TB = Tie Breaker

•

TB2 = Tie Breaker 2

•

Front Panel Display Structure

The display structure of the Main Menu screens is provided below.

Metering

• Engine

o Oil Pressure o Coolant Temperature o Battery Voltage o Engine Speed o Speed Source o Fuel Level o Engine Load o Coolant Level o Total Run Time o Hours to Maintenance o DEF Tank 1 Level (Visible when ECU Type is Standard, Volvo Penta, MTU SMC, MTU

ADEC, GM/Doosan, Cummins, MTU SMC)

o DEF Tank 2 Level (Visible when ECU Type is Standard, Volvo Penta, MTU SMC, MTU

ADEC, GM/Doosan, Cummins, MTU SMC)

• Gen

o Voltage o Current o Frequency o Power o Energy o Vector Shift

• Bus 1

o Voltage o Current o Fr

equency

o Power o Energy

Vector Shift

• Bus 2

o Voltage o Current o Frequency o Power o Energy o Vector Shift

• Synchronization

• Differential

o Phase A o Phase B o Phase C o Phase Neutral

• Bias Control

Var Mode

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

o PF Mode o Op Baseload Level o Op kvar Setpoint o Op PF Setpoint

• Run Statistics

o Cumulative o Session

• Status

o Status o Bus Condition o IO Module Connected o Run Request o Mains Power Control

• Inputs

o Contact Inputs o Analog Input Values o Remote Contact Inputs o Remote Analog Input Values o Logic Control Relays o Remote System Manager Inputs o Broadcast Logic

• Outputs

o Contact Outputs o Analog Outputs o Configurable Elements o Remote Contact Outputs o Remote Analog Outputs

• Configurable Protection

o Configurab

• Alarms

• Pre-Alarms

• Event Log

o Show Log o Reset

• J1939 ECU

o J1939 Data (Visible when CAN Bus 2 ECU Support is enabled.) o J1939 Engine Config (Visible when CAN Bus 2 ECU Support is enabled.) o DTC Active Data (Visible when CAN Bus 2 ECU and DTC Support are enabled.) o DTC Previous Data (Visible when CAN Bus 2 ECU and DTC Support are enabled.)

• MTU

o MTU Fault Codes (Visible when selected ECU type is MTU MDEC, MTU ADEC, MTU

ECU7/8, and MTU Smart Connec MTU Status (Visible when selected ECU type is MTU MDEC, MTU ADEC, MTU ECU7/8, and MTU Smart Connect.)

le Protection 1 to Configurable Protection 32

t.)

• System Status

o System Breaker Status o System Mains Bus o System Group Bus o System Load Bus o Power Breaker Sum

• Real Time Clock

• Gen Network Status

o Units o Act Seg Units o Units Online o Sys Online kW Cap

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 73

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

o Sys Online kvar Cap o Sys Generated kW o Sys Generated kW Percent o Sys Generated kvar o Sys Total kW Cap o ID1 to ID32

• Gen Sequencing

o Mode o Next to Start o Next Start UID o Next to Stop o Next Stop UID o Start Timer 1 o Start Timer 2 o Stop Timer o Seq Mode o Sequence ID o Unit ID o Active Seg ID o Sys Manager o Sys Man UID o Start TD 1 o Start TD 2 o Stop TD

• Load Shedding

o Sys Total Seq Reserve o Sys Online Reserve o Priority to Shed o Shed Delay o Shed Fast Delay o Priority to Add o Add Delay o Demand Start o Load 1 to

• Reports

o Sequence of Events o Security Log

• Diagnostics

o Control o Load Share Line o AEM-2020 o CEM-2020 o Mains Power

• General Settings

o Front Panel HMI o Device Information o Access Control o Clock Setup o Display Units

• Communication

o Ethernet o Ethernet 2 (Visible when redundant Ethernet is disabled.) o Redundant Ethernet o CAN Bus 1 (I/O) Setup o CAN Bus 2 (ECU) Setup

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Settings

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

o Modem Setup o RS485 Setup o RS232 Setup o Modbus Setup o Email Setup

• System Parameters

o System Settings o Group Settings o Rated Data o Sensing Transformers o Remote Module Setup o Crank Settings o Auto Restart o Exercise Timer o Relay Control o Auto Config Detect o Engine Statistics o Seven Day Timer

• Report Configuration

o Data Log o Trending o Sequence of Events Setup

• Programmable Inputs

o Contact Inputs o Analog Inputs

o Programmable Functions o Remote Contact Inputs o Remote Analog Inputs o Remote RTD

o Remote Thermocouple Inputs

o Remote Sys Manager Inputs

• Programmable Outputs

o Output Contacts

o Configurable Elements

o Remote Contact Outputs

o Remote Analog Outputs

• Alarm Configuration

o Horn Configuration

o Pre-Alarms

o Alarms

o Sender Fail

o Prog Alarms

• Protection

o Settings Group 0 o Settings Group 1 o Settings Group 2 o Settings Group 3 o Configurable Protection

• Breaker Management

o Breaker Management o Breaker Hardware o Bus Condition o Synchronizer o Breaker Power Sum

• Bias Control

o AVR Bias Contro

o GOV Bias Control

o Mains Power Control

Inputs

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 75

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

• Multigen Management

o AVR Output o GOV Output o LS (Load Share) Output o Demand Start/Stop o Sequencing o Network Configuration o Load Shedding

• Logic

o Logic Timers (1-8) o Logic Timers (9-16) o Logic Counters o Broadcast Logic

Summary

• System Configuration One-Line Diagram

• Mains Fail St (Status)

o Mains Fail St (Status) o Transfer Delay o Max Transfer Time o Return Delay o Return Timer o Max Parallel Time o Open Transition Delay

• Gen VLL

• Gen Hz

• Gen Aac

• kW

• kvar

• PF (Power Factor)

• PF Lead/Lag

• Bus1 VLL

• Bus1 Hz

• Bus2 VLL (optional)

• Bus2 Hz (optional)

• GB Command (Visible when Generator Breaker control is enabled.)

o Open, Close, or None

• GGB Command (Visible when Generator Group Breaker control is enabl

o Open, Close, or None

• MB Command (Visible when Mains Breaker control is enabled.)

o Open, Close, or None

• TB Command (Visible when Tie Breaker control is enabled.)

o Open, Close, or None

• TB2 Command (Visible when Tie Breaker 2 control is enabled.)

o Open, Close, or None

ed.)

Display Setup

BESTCOMSPlus®Navigation Path: Settings Explorer, General Settings, Front Panel HMI

Front Panel Navigation Path: Settings > General Settings > Front Panel HMI

The DGC-2020HD LCD can be customized to fit the needs of your specific application. Most of the options can be adjusted using the front panel buttons while all options can be adjusted within BESTCOMSPlus. The display options are described below. Figure F shows the BESTCOMSPlus Front Panel HMI settings screen. Settings ar

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e listed in Table B.

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

Locator

Setting

Range

Increment

Unit

Contrast Value

0 to 100

Invert Display

Enabled or Disabled

n/a

Sleep Mode

Enabled or Disabled

n/a

LCD Backlight Timeout

1 to 120

minutes

English, French, Spanish,

or German

Enable Scroll

Enabled or Disabled

n/a

Scroll Time Delay

1 to 600

varies

seconds

Phase Toggle Delay

0 to 120

seconds

Up to 16 alphanumeric

characters

Touchscreen Disable

Enabled or Disabled

n/a

Figure F. Front Panel Settings Screen

Table B. Settings for Front Panel Settings Screen

E Language Selection

I Initializing Message

n/a n/a

DCA220SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (02/10/17) — PAGE 77

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BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)

LCD Contrast

Adjust this setting to compensate for your LCD viewing angle, the available ambient light, or the ambient temperature. This setting accepts values from 0 to 100, in increments of 1 percent.

Invert Display

When enabled, the LCD background is dark with light text.

Sleep Mode

Select enabled to send the DGC-2020HD into sleep mode during periods of inactivity to minimize battery drain.

LCD Backlight Timeout

When Sleep Mode is enabled, this setting dictates the amount of time that must elapse before the DGC2020HD enters sleep mode. This setting accepts values from 1 to 120, in increments of 1 minute.

Language Selection

Front panel text is displayed in the selected language. Select English, French, Spanish, or German.

Screen Scrolling Setup

When scrolled metering is enabled, user-selected metering values are displayed on the overview screen. Any number of the available values can be displayed. Up to nine values are displ one time, after the scroll time delay has elapsed, the next set of values is displayed and so on.

ayed on the screen at

Initializing Messages

Two custom initializing messages are displayed on the boot screen of the DGC-2020HD.

Touchscreen Disable

When checked, the touch screen controls are disabled.

Splash Screen

BESTCOMSPlus®Navigation Path: Settings Explorer, General Settings, Splash Screen Front Panel Navigation Path: Not available through front panel

A splash screen, which is displayed for a few seconds upon powering up the DGC-2020HD, can be customized. The image must be exactly 480 pixels wide and 272 pixels high. Acceptable image formats are BMP, JPG, GIF, and PNG. This is only available to units with the optional color touch screen (style xTxxxxxxx).

Connect to the unit us the desired image, select it, and click Open. If successful, the image appears in the Splash Screen in BESTCOMSPlus. Upload settings to the DGC-2020HD to transfer the image.

ing BESTCOMSPlus. Click the Browse button on the Splash Screen, navigate to

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NOTES

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OPERATION MANUAL

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MQ Power DCA220SSJU4F Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual