OPERATION AND PARTS MANUAL
WHISPERWATTTM SERIES
MODEL DCA-25SSIU2
60 Hz GENERATOR
PARTS LIST NO. M1870300804
Revision #0 (01/27/06)
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES.
PAGE 2 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ POWER CORPORATE OFFICE |
|
18910 Wilmington Ave. |
800-421-1244 |
Carson, CA 90746 |
FAX:310-632-2656 |
Email:mqpower@multiquip.com |
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Internet:www.mqpower.com |
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PARTS DEPARTMENT |
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800-427-1244 |
FAX:800-672-7877 |
310-537-3700 |
FAX:310-637-3284 |
SERVICE DEPARTMENT |
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800-835-2551 |
FAX:310-638-8046 |
310-537-3700 |
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TECHNICAL ASSISTANCE |
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800-835-2551 |
FAX:310-638-8046 |
WARRANTYDEPARTMENT |
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800-835-2551, EXT. 279 |
FAX:310-638-8046 |
310-537-3700, EXT. 279 |
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© COPYRIGHT 2005, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the DCA-25SSIU2 (60 HZ)Whisperwatt™ Generator.Multiquip Inc.reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.
To find the latest revision of this publication, visit our website at: www.mqpower.com
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 3
MQ POWER DCA-25SSIU2 (60 HZ)
WHISPERWATT™ GENERATOR
California Proposition 65 Warning ..................................... |
2 |
Here's How To Get Help .................................................... |
3 |
Table Of Contents ............................................................. |
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Parts Ordering Procedures ............................................... |
5 |
Specifications ................................................................... |
6 |
Dimensions ( Side, Front) ................................................. |
7 |
Safety Message Alert Symbols .................................... |
8-9 |
Rules for Safe Operation ........................................... |
10-13 |
Generator Decals....................................................... |
14-15 |
Installation ................................................................. |
16-17 |
General Information ........................................................ |
18 |
Major Components ......................................................... |
19 |
Generator Control Panel ................................................. |
20 |
Engine Operating Panel .................................................. |
21 |
Output Terminal Panel Familiarization ........................ |
22-24 |
Load Application ............................................................. |
25 |
Generator Outputs .......................................................... |
26 |
Gauge Reading ............................................................... |
27 |
Output Terminal Panel Connections ........................... |
28-29 |
Pre Setup .................................................................. |
30-33 |
Generator Start-up Procedure ................................... |
34-36 |
Generator Shut-Down Procedure .................................... |
36 |
Maintenance .............................................................. |
37-38 |
Trailer Maintenance.................................................... |
39-42 |
Trailer Wiring Diagram ..................................................... |
43 |
Generator Wiring Diagram ............................................... |
44 |
Engine Wiring Diagram ................................................... |
45 |
GeneratorTroubleshooting .............................................. |
46 |
Engine Troubleshooting ............................................. |
47-48 |
Explanation of Code in Remarks Column ....................... |
50 |
Suggested Spare Parts .................................................. |
51 |
TABLE OF CONTENTS
COMPONENT DRAWINGS
Generator Assembly ............................................ |
52-53 |
Control Box Assembly.......................................... |
54-57 |
Engine Operating Panel Assembly...................... |
58-59 |
Engine & Radiator Assembly ............................... |
60-63 |
Output Terminal Assy. .......................................... |
64-65 |
Battery Assembly ................................................. |
66-67 |
Muffler Assembly ................................................. |
68-69 |
Fuel Tank Assembly ............................................. |
70-71 |
Enclosure Assembly ............................................ |
72-75 |
Rubber Seal Assembly ........................................ |
72-73 |
Name Plate And Decals ....................................... |
74-75 |
Rubber Seal Assembly ........................................ |
76-77 |
Nameplate and Decals ........................................ |
78-79 |
Terms and Condition of Sale — Parts...................... |
80 |
Specification and part NOTE number are subject to
change without notice.
PAGE 4 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
Dealer account number
Dealer name and address
Shipping address (if different than billing address)Return fax number
Applicable model number
Quantity, part number and description of each partSpecify preferred method of shipment:
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Truck
Note:Unlessotherwiseindicatedbycustomer,all orders are treated as “Standard Orders”, and will ship within 24 hours.We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.
Here’s how to get help...
Please have the model and serial number on hand when calling.
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave. |
800-421-1244 |
Carson, CA 90746 |
FAX: 310-632-2656 |
Email: mqpower@multiquip.com |
|
Internet: www.mqpower.com |
|
PARTS DEPARTMENT |
|
800-427-1244 |
FAX: 800-672-7877 |
310-537-3700 |
FAX: 310-637-3284 |
SERVICE DEPARTMENT |
|
800-835-2551 |
FAX: 310-638-8046 |
310-537-3700 |
|
TECHNICAL ASSISTANCE |
|
800-835-2551 |
FAX: 310-638-8046 |
WARRANTY DEPARTMENT |
|
800-835-2551, EXT. 279 |
FAX: 310-638-8046 |
310-537-3700, EXT. 279 |
|
Place Your Parts Order Via Web or Fax For Even More Savings!
(Domestic USA Dealers Only)
Extra Discounts!
All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:
Ordered |
Standard |
Stock orders |
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via |
orders |
($750 list and above) |
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Fax |
3% |
10% |
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Web |
5% |
10% |
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Special freight allowances when you order 10 or more line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MQPOWER |
Direct TOLL-FREE access |
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A Division of Multiquip Inc. |
to our Parts Department: |
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POST OFFICE BOX 6254 |
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CARSON, CA 90749 |
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310-537-3700 • 800-421-1244 |
Toll-free nationwide — 800-427-1244 |
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FAX:310-632-2656 |
Toll-free FAX — 800-6-PARTS-7 (800/672-7877) |
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E-MAIL:mqpower@multiquip.com |
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INTERNET: www.mqpower.com |
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DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 5
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DCA-25SSIU2 (60 HZ)— SPECIFICATIONS |
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Table 1. Generator Specifications |
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Model |
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DCA-25SSIU2 |
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Type |
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Revolving field, self ventilated, open protected type synchronous |
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generator |
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Armature Connection |
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Star with Neutral |
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Zig Zag |
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Phase |
3 |
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Single |
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Standby Output |
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27.5 KVA (22)KW |
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15.8 KW |
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Prime Output |
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25 KVA (20 KW) |
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14.4 KW |
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Voltage |
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240V or 480V |
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240/120V |
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Frequency |
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60 Hz |
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Speed |
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1,800 rpm |
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Power Factor |
0.8 |
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1 |
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Aux. AC Power |
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Single Phase, 60 Hz |
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Voltage |
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120 VAC |
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Output |
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4.8 KW (2.4 KW x 2) |
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Table 2. Engine Specifications |
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Model |
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ISUZU AA-4LE2 |
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Type |
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4 Cycle, water-cooled, direct injection |
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No. of Cylinders |
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4 cylinders |
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Bore x Stroke |
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3.35 in. x 3.78 in. (85 mm x 96 mm) |
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Displacement |
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132 cu. in. (2,179 cc) |
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Starting |
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Electric |
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Coolant Capacity |
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1.7 gal. (6.4 liters) |
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Lube Oil Capacity |
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2.24 gal. (8.5 liters) |
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Fuel Tank Capacity |
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17.2 gal. (65 liters) |
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Fuel Consumption |
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1.44 gal. (5.47 L)/hr at full load |
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Battery |
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27 (CCA 0° F 525A) X1 |
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Fuel |
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#2 Diesel Fuel |
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PAGE 6 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— DIMENSIONS (TOP, SIDE AND FRONT)
TABLE 3. DIMENSIONS
Reference |
Dimension ft. (mm.) |
Reference Letter |
Dimension ft. (mm.) |
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Letter |
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A |
26.37 in. (670 mm.) |
F |
72.83 in. (1,850 mm.) |
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B |
25.00 in. (635 mm.) |
G |
39.37 in. (1,000 mm.) |
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C |
21.06 in. (535 mm.) |
H |
29.52 in. (750 mm.) |
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D24.21 in. (615 mm.)
E21.06 in. (535 mm.)
Figure 1. Dimensions
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 7
DCA-25SSIU2 (60 HZ) — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY AND THE SAFETY OF OTHERS! |
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HAZARD SYMBOLS |
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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.
This OperationandPartsManual
NOTE
has been developed to provide complete instructions for the safe and efficient operation of the MQ Power Model DCA-25SSIU2
(60Hz) Whisperwatt™Generator.
Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you do not follow directions.
WARNING
You COULD be KILLED or SERIOUSLY injured if you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
Potential hazards associated with the operation of this equipment will be referenced with "Hazard Symbols" which appear throughout this manual, and will be referenced in conjunction with Safety "Message Alert Symbols".
WARNING - LETHAL EXHAUST GASES
Diesel engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
Diesel fuel is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
WARNING - BURN HAZARDS
Engine components can generate extreme heat.To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there exists the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even DEATH!
PAGE 8 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ) — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF switch in the OFF position and remove the ignition key when the pump is not in use.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings of the engine governor or settings.
Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.
This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.
CAUTION - RESPIRATORY HAZARDS
ALWAYS wear approved respiratory protection.
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS wear approved eye and hearing protection.
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 9
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
DANGER - READTHIS MANUAL!
Failure to follow instructions in this manual may lead to serious injury or even DEATH! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.
The following safety guidelines should always be used when operating the DCA-25SSIU2 (60 HZ) Generator:
General Safety:
■DO NOT operate or service this equipment before reading this entire manual.
The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.
■This equipment should not be operated by persons under
18 years of age.
■NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.
■ NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.
■NEVER operate this equipment under the influence or drugs or alcohol.
■NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.
■Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.
■Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.
■ALWAYS check the machine for loosened threads or bolts before starting.
■NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death.
■NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.
■ HighTemperatures – Allow the engine to cool before performing service and maintenance functions. Contact with hot! components can cause serious
burns.
■The engine of this generator requires an adequate free flow of cooling air. NEVER operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is
restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.
■DO NOT place hands or fingers inside generator engine compartment when engine is running.
■NEVER run engine without air filter.Severe engine damage may occur.
■DO NOT leave the generator running in the manual mode unattended.
■Refer to the Isuzu Engine Owner's Manual for engine technical questions or information.
■ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.
PAGE 10 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
Generator Grounding
To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.
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.
The following safety recommendations should also be followed:
■ALWAYS make sure generator is properly grounded.
■NEVER use gas piping as an electrical ground.
■ALWAYS make sure that electrical circuits are properly grounded per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or
DEATH! by electrocution can result from operating an ungrounded generator.
■ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.
Electrical Safety
■ALWAYS have a qualified electrician perform the generator wiring installation.
■ALWAYS make sure generator installation is accordance with the National Electrical Code (NEC) and local codes before operating generator.
■NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.
■NEVER use a extension cord that is frayed or damaged where the insulation has been cut.
■ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.
■NEVER power cables or cords lay in water.
■NEVER stand in waterwhile AC power from the generator is being transfer to a load.
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there exists the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even DEATH!
To avoid these hazards:
NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator
and electrical shock.
NEVER grab or touch a live power cord with wet hands.
NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.
Backfeed to a utility system can cause electrocution and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened.
ALWAYS have a licensed electrician perform the installation
POWER
CORD
(POWER ON)
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 11
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
Maintenance Safety
■The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn all circuit breakers OFF before performing maintenance on the generator.
■NEVER lubricate components or attempt service on a running machine.
■ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.
■Follow all Battery Safety Guidelines listed in this manual when handling or servicing the generator.
■ALWAYS allow the machine a proper amount of time to cool before servicing.
■Keep the machinery in proper running condition.
■Fix damage to the machine immediately and always replace broken parts.
■ALWAYS service air cleaner frequently to prevent engine malfunction.
WARNING - BURN HAZARDS
To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is
running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.
■Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.
■Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.
■Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.
Battery Safety
Use the following guidelines when handling the battery:
■The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses.
■Use well insulated gloves when picking up the battery.
DANGER - EXPLOSION HAZARDS
The risk of an explosion exists when performing service on the battery. To avoid severe injury or DEATH:
■DO NOT drop the battery.There is the possibility of risk that the battery may explode.
■DO NOT expose the battery to open flames, sparks, cigarettes
etc.The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame or spark, an explosion could occur.
■ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.
■ALWAYS keepbatterychargingandcablesin good working condition. Repair or replace all worn cables.
■ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.
■In case the battery liquid (dilute sulfuric acid) comes in contact with clothing or skin, rinse skin or clothing immediately with plenty of water.
■In case the battery liquid (dilute sulfuric acid) comes in contact with your EYES, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.
PAGE 12 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
Towing &Transporting Safety
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 in good operating condition and both units are mechanically sound.
The following list of safety precautions should be followed when towing your generator:
CAUTION - FOLLOWTOWING REGULATIONS
Check with your local county or state safety towing regulations, in addition to meeting Department of Transportation (DOT) SafetyTowing Regulations, before towing your generator.
■ALWAYS shutdown engine before transporting.
■Tighten both fuel tank caps securely.
■If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed Towing & Transporting Safety guidelines for basic towing techniques.
■Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”
■ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.
■Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
■ALWAYS make sure the trailer is equipped with a "Safety Chain".
■ALWAYS attach trailer’s safety chains to towing vehicle properly.
■ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.
■DOT Requirements include the following:
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie wraps.
■The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.
■Place chock blocks underneath wheel to prevent rolling, while parked.
■Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.
■Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.
■Avoid sharp turns.
■Trailer should be adjusted to a level position at all times when towing.
■Raise and lock trailer wheel stand in up position when transporting.
■The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.
■Place support blocks underneath the trailer’s bumper to prevent tipping, while parked.
■Avoid sharp turns to prevent rolling.
■DO NOT transport generator with fuel in tank.
Emergencies
■ALWAYS know the location of the nearest fire extinguisher.
■ALWAYS know the location of the nearest and first aid kit.
■ALWAYS know the location of the nearest phone or keep a phone on the job site, in case of emergencies.
■ALWAYS have easy access to the phone numbers of the nearest Ambulance, Doctor and Fire Department. This information will be invaluable in the case of an emergency.
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 13
DCA-25SSIU2 (60 HZ)— GENERATOR DECALS
The DCA-25SSIU2 (60 Hz)Whisperwatt™ Generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
Figure 2. Generator Decals
PAGE 14 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— GENERATOR DECALS
Figure 3. Generator Decals (Continued)
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 15
DCA-25SSIU2 (60 HZ)— INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 16 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— 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 - EXHAUST HAZARD
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.
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.
Generator Grounding
To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. See Figure 4 for a typical grounding configuration.
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 - 10 AWG (5.3 mm2) or larger.
b.Aluminum - 8 AWG (8.4 mm2) or larger.
2.When grounding the generator (Figure 5) 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.
3.NEC article 250-52(c) specifies that the earth ground rod should be buried aminimum of 8 ft. into the ground.
When connecting the generator NOTE to any buildings electrical system ALWAYS consult with
a licensed electrician.
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 17
DCA-25SSIU2 (60 HZ)— GENERAL INFORMATION
DCA-25SSIU2 (60 Hz) Series Familiarization
Generator
The MQ Power Model DCA-25SSIU2 (60 Hz) is a 20 kW generator (Figure 5) that 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.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■Tachometer
■WaterTemperature Gauge
■WaterTemperature Alarm Lamp
■Oil Pressure Gauge
■Oil Pressure Alarm Lamp
■Charging Ammeter Gauge
■Fuel Level Gauge
■Pre-heat Lamp
■Panel Light/Panel Light Switch
■Ignition Switch
■Fuel Filter Water Level Alarm Lamp
Generator Control Panel
The “Generator 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, 60 amp Main Circuit Breaker
■“Control Box” (located behind the Gen. Control Panel)
■Automatic Voltage Regulator
■CurrentTransformer
■Over-Current Relay
■Voltage Rectifier
■Starter Relay
■Voltage Selector Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
■Two 120/240V output receptacles (CS-6369), 50A
■Two auxiliary circuit breakers, 50A
■Two 120V output receptacles (GFCI), 20A
■Two GFCI circuit breakers, 20A
■Five output terminal lugs (3Ø power)
■Battery Charger (Optional)
■Water Heater (Optional)
Open Delta Excitation System
The DCA-25SSIU2 (60 HZ) generator is equipped with the state of the art "Open-Delta" 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.
PAGE 18 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— MAJOR COMPONENTS
Table 4. Generator Major Components
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ITEM NO. |
DESCRIPTION |
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1 |
Output Terminal Panel Assembly |
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2 |
Output Receptacles Assembly |
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3 |
Air Filter Assembly |
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4 |
Muffler Assembly |
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5 |
Fuel Tank Assembly |
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6 |
Engine Assembly |
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7 |
Battery Assembly |
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8 |
Generator Assembly |
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9 |
Engine Operating Panel Assembly |
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10 |
Generator Control Panel Assembly |
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Figure 5. Major Components
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 19
DCA-25SSIU2 (60 HZ)— GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of the
DCA-25SSIU2 (60 HZ) Generator Control Panel (Figure 6).
1.Main Circuit Breaker – This three-pole, 60A main breaker is provided to protect the U,V, and W Output Terminal Lugs from overload.
2.Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage
3.Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz.
4.AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.
5.ACVoltmeter – Indicates the output voltage present at the U,V, and W Output Terminal Lugs.
6.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.
7.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.
Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.
The Control Box is equipped with the following major components:
■Over-Current Relay
■Voltage Rectifier (AVR)
■Starter Relay
■CurrentTransformer
■Voltage Selector Switch
Remember the overcurrent NOTE 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 60 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 20 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— ENGINE OPERATING PANEL
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Figure 7. Engine Operating Panel |
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The definitions below describe the controls and functions of 7. |
Pre-heat Lamp - |
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the DCA-25SSIU2 (60 HZ) "Engine Operating Panel " |
ready for starting |
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(Figure 7). |
conditions. |
This indicates when the engine is during cold weather operating
1.Panel Light - Normally used in dark places or at night. 8. Tachometer – Indicates engine speed in RPM’s for 50
When activated, panel will illuminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.
2.Panel Light Switch-When activated, will turn on control panel light.
Hz operation. This meter should indicate 1500 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.
9.Fuel Gauge - Indicates amount of diesel fuel available.
3.Oil Pressure Alarm Lamp - Indicates that the oil 10. Charging Ammeter Gauge – Indicates the current
pressure is too low or high and will shut down the engine.
4.Water Temperature Alarm Lamp - Indicates that the water temperature is outside of normal range and will shut down the engine.
5.Fuel Filter Water Lever Alarm Lamp - Indicates that water level in the fuel level has risen. Drain the water in the fuel filter strainer when this condition occurs.
6.Ignition Switch –Three position switch, stop, operation and start. Insert ignition key to start and stop engine.
being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.
11.WaterTemperature Gauge – During normal operation this gauge be should read between 165o F to 203o F.
12.Oil Pressure Gauge – Normal operation should be between 28 ~71 psi (193 ~490 kPa). When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 21
DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The OutputTerminal Panel (Figure 8) shown below is located on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal lugs.
NOTE |
Terminal legs “O” and “Ground” |
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are considered bonded grounds. |
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Output Terminal Familiarization
The “OutputTerminal Panel ” (Figure 9) is provided with the following:
■120/240V output receptacles (2) @ 50 amp
■Circuit Breakers (2) @ 50 amps, 2-pole
■120V GFCI receptacles (2) @ 20 amp
■GFCI Circuit Breaker (2) @ 20 amps, 1-pole
■Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Figure 8. Output Terminal Panel
PAGE 22 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 9. G.F.C.I. Receptacle
120VAC GFCI Receptacles
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch 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 9) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.
Figure 10. 120/240VTwist-Lock
Auxiliary Receptacles
Twist Lock DualVoltage 120/240VAC Receptacles
There are two 120/240V, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the singlephase 240/120 position.
Figure 11. Voltage Regulator Control Knob
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
OutputTerminal Lugs.
Turn the voltage regulator control knob (Figure 11) on the control panel to obtain the desired voltage.Turning the knob clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.
Removing the Plastic Face Plate (HardWire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.
After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.
Figure 12. Plastic Face Plate (Output Terminal Lugs)
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 23
DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 13).
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, 60A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.
Figure 13. Connecting Loads
Figure 14. Over Current Relay
Over Current Relay
An over current relay (Figure 14) 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.
Blower Fan
This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the Voltage Selector Switch (Figure 15).
Figure 15. Blower Fan Fuse
DANGER - ELECTROCUTION HAZARDS
This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating
could result in electrocution and severe bodily harm. ALWAYS turn the unit completely off before attempting to replace or handle this fuse.
PAGE 24 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— 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.
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 5 below when connecting loads.
Table 5. Power Factor By Load
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Type Of Load |
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Power Factor |
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Single-phase induction motors |
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0.4 - 0.75 |
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Electric heaters, incandescent |
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lamps |
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Fluorescent lamps, mercury lamps |
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0.4 - 0.9 |
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Electronic devices, communication |
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1.0 |
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equipment |
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Common power tools |
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0.8 |
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Table 6. Cable Selection (60 Hz, Single Phase Operation) |
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Current in |
Load In Watts |
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Maximum Allowable Cable Length |
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Amperes |
At 120 |
At 240 |
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#10 Wire |
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#12 Wire |
#14 Wire |
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#16 Wire |
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Volts |
Volts |
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2.5 |
300 |
600 |
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1000 ft. |
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600 |
ft. |
375 ft. |
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250 ft. |
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5 |
600 |
1200 |
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500 |
ft. |
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300 |
ft. |
200 ft. |
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125 ft. |
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7.5 |
900 |
1800 |
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350 |
ft. |
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200 |
ft. |
125 ft. |
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100 ft. |
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10 |
1200 |
2400 |
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250 |
ft. |
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150 |
ft. |
100 ft. |
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15 |
1800 |
3600 |
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150 |
ft. |
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100 |
ft. |
65 ft. |
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20 |
2400 |
4800 |
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125 |
ft. |
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75 ft. |
50 ft. |
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CAUTION: Equipment damage can result from low voltage. |
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Three Phase Load
When calculating the power requirements for 3-phase power use the following equation:
If 3Ø load (kVA) is not given on the equipment nameplate,
NOTE approximate 3Ø load output maybedeterminedbymultiplying voltage by amperage by 1.732.
Motors and motor-driven NOTE 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 - ELECTRICAL SYSTEM HAZARDS
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 switch.
DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 25