Multiquip DCA150USJ User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
ULTRA-SILENT
TM
SERIES
MODEL DCA-150USJ
GENERATOR
PARTS LIST NO. M3870400104
Revision #1 (01/15/08)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
DCA-150USJ — PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
NOTES
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 3
TABLE OF CONTENTS
MQ POWER DCA-150USJMQ POWER DCA-150USJ
MQ POWER DCA-150USJ
MQ POWER DCA-150USJMQ POWER DCA-150USJ
ULUL
TRA-SILENT GENERATRA-SILENT GENERA
UL
TRA-SILENT GENERA
ULUL
TRA-SILENT GENERATRA-SILENT GENERA
California Proposition 65 Warning ..................................... 2
Here's How To Get Help ....................................................3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ...............................................5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) ...........................................7
Safety Message Alert Symbols .................................... 8-9
Rules for Safe Operation ........................................... 10-13
Installation ................................................................. 14-15
Towing Safety Precaution ............................................... 16
Trailer Specifications ...................................................... 17
Generator Decals....................................................... 18-19
General Information ........................................................ 20
Major Components ......................................................... 21
Generator Control Panel ................................................. 23
Engine Operating Panel ............................................. 24-25
Output Terminal Panel Familiarization ........................ 26-28
Load Application ............................................................. 29
Generator Outputs ..................................................... 30-31
Gauge Reading ............................................................... 31
Output Terminal Panel Connections ........................... 32-33
Pre Setup .................................................................. 34-37
Generator Start-up Procedure (Manual) ..................... 38-40
Generator Start-up Procedure (Auto Mode) .................... 41
Generator Shut-Down Procedure .................................... 42
Maintenance .............................................................. 43-45
Trailer Brakes Maintenance ............................................ 46
Trailer Maintenance .................................................... 47-48
Trailer Wiring Diagram ..................................................... 49
Generator Wiring Diagram ............................................... 50
Engine Wiring Diagram ................................................... 51
Generator Troubleshooting .............................................. 52
Engine Controller Troubleshooting ................................... 53
Explanation of Code in Remarks Column ....................... 54
Suggested Spare Parts .................................................. 55
TORTOR
TOR
TORTOR
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly .................................................. 56-57
Control Box Assembly ............................................... 58-61
Engine & Radiator Assembly ..................................... 62-65
Output Terminal Assembly ......................................... 66-67
Battery Assembly ...................................................... 68-69
Muffler Assembly ...................................................... 70-71
Fuel Tank Assembly .................................................. 72-73
Enclosure #1 Assembly ............................................ 74-77
Enclosure #2 Assembly ............................................ 78-79
Rubber Seals Assembly ............................................ 80-81
Nameplate and Decals .............................................. 82-83
Terms and Condition of Sale — Parts ............................ 84
NOTE
Specification and part
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
Best Deal!
r
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
■
Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Use the
on
complete part numbers.*
Fax
on
Standard orders
complete part numbers.*
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact you
District Sales Manager for more information.
internet
and qualify for a 5% Discount
Standard orders
your order in and qualify for a 2% Discount
Effective:
January 1
for all orders which include
Note: Discounts Are Subject To Change
st
, 2006
for all orders which include
Note: Discounts Are Subject To Change
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒❒
❒
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 Part
❒❒
All orders are treated as
and will ship the same day if received prior
to 3PM PST.
Domestic (US) Dealers Call:
1-800-427-1244
International Customers
their local Multiquip Representatives for
Parts Ordering information.
❒❒
❒
Specify Preferred Method of Shipment:
❒❒
✓
UPS/Fed Ex
■
Priority One
■
Ground
■ Next Day
■
Second/Third Day
Standard Orders
should contact
✓ DHL
✓
Tr u ck
www.mqpower.com
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 5
WE ACCEPT ALL MAJOR CREDIT CARDS!
1
DCA-150USJ — SPECIFICATIONS
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PAGE 6 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 7
1
DCA-150USJ — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
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 Owner's Manual has been
NOTE
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power
Model DCA-150USJ
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
appear throughout this manual, and will be referenced in
conjunction with Safety "
WARNING - LETHAL EXHAUST GASES
ULTRA-SILENT™ 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.
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
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.
Hazard Symbols
Message Alert Symbols
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH
if inhaled. NEVER operate this
Gasoline
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.
is extremely flammable, and
" which
".
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
PAGE 8 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
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
electrical shock or burn,
severe bodily harm
electrocution,
which can cause
or even
DEATH!
DCA-150USJ — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep
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.
fingers, hands
CAUTION - RESPIRATORY HAZARDS
,
CAUTION - SIGHT AND HEARING HAZARDS
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.
ALWAYS wear approved
protection.
ALWAYS wear approved
hearing
protection.
respiratory
eye
and
NOTE
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 9
DCA-150USJ — RULES FOR SAFE OPERATION
■
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury
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-150USJ 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.
or even
DEATH
! This equipment is to be
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
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■
High Temperatures – 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.
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.
bodily harm or even death.
NEVER
operate the generator in any
■
■
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.
■
■
■
■
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
unattended.
Refer to the
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.
John Deere Engine Owner's Manual
manual mode
for
PAGE 10 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of
electrical shock or burn,
Article 250 (Grounding) of the
National Electrical Code
severe bodily harm
(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:
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
■
ALWAYS make sure generator is properly grounded.
■
NEVER use gas piping as an electrical ground.
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
DEATH!
per the
National Electrical Code
(NEC) and
injury
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.
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
or
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.
electrocution,
which can cause
or even
DEATH!
POWER
CORD
(POWER ON)
WET
HANDS
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 5.
■
NEVER power cables or cords
■
NEVER
stand in water
while AC power from the generator
lay in wate
r.
is being transfer to a load.
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
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 11
DCA-150USJ — 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.
before performing maintenance on the generator.
■
NEVER lubricate components or attempt service on a
running machine.
■
ALWAYS disconnect the
before performing service on the generator.
■
Follow all Battery Safety Guidelines listed in this manual
when handleing 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.
Turn all circuit breakers OFF
NEGATIVE battery terminal
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,
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
■■
■
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 keep battery charging and cables in 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
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
always
clothing or skin
EYES
wear safety
severe injury
, rinse eyes immediately with
or
DEATH:
, rinse skin or clothing
■
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.
PAGE 12 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — 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 the generator:
CAUTION - FOLLOW TOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting
Transportation
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
guidelines for basic towing techniques.
(DOT)
Safety Towing Regulations
Towing & Transporting Safety
Department of
, before
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
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 to prevent rolling.
■
Trailer should be adjusted to a level position at all times
when towing.
■
Raise and lock trailer wheel stand in up position when
transporting.
■
Place
prevent tipping, while parked.
■
DO NOT transport generator with fuel in tank.
Emergencies
chock blocks
support blocks
underneath wheel to prevent rolling,
underneath the trailer’s bumper to
■
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.
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:
z
z
Trailer tires should be inflated to 50 psi cold.
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
■
■
■
■
ALWAYS know the location of the
nearest
ALWAYS know the location of the
nearest and
ALWAYS know the location of the
nearest phone or
the job site,
ALWAYS have easy access to the phone
numbers of the nearest
and
be invaluable in the case of an emergency.
fire extinguisher
first aid kit
keep a phone on
in case of emergencies.
Fire Department
.
.
Ambulance, Doctor
. This information will
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 13
DCA-150USJ — GENERATOR DECALS
The DCA-150USJ 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-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 15
1
DCA-150USJ — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 16 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — 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
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.
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 mm
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 4) 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 a minimum of 8 ft. into the ground.
2
) or larger.
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.
NOTE
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 17
DCA-150USJ — GENERAL INFORMATION
DCA-150USJ Series Familiarization
Generator
The MQ Power Model DCA-150USJ is a 120 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
■■
■■
■
Water Temperature Gauge
■■
■■
Oil Pressure Gauge
■
■■
■■
■
Charging Ammeter Gauge
■■
■■
■
Fuel Level Gauge
■■
■■
■
Pre-heat Lamp
■■
■■
■
Panel Light/Panel Light Switch
■■
■■
■
Auto ON/OFF Engine Controller (MPEC)
■■
■■
■
Fuel Leak Detected 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, 400 amp Main Circuit Breaker
■■
■■
■
“Control Box” (located behind the Gen. Control Panel)
■■
■■
■
Automatic Voltage Regulator
■■
■■
■
Current Transformer
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer
■■
■■
■
Starter Relay
■■
■■
■
Engine Controller (Electronically Controlled)
■■
■■
■
Voltage Selector Switch
■■
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
■■
■
Three 120/240V output receptacles (CS-6369), 50A
■■
■■
■
Three auxilliary 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-150USJ generator is equipped with the state of
the art "
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 "
according the demands of the required load.
Engine
The DCA-150USJ is powered by a 4 cycle, water cooled,
direct injection, turbocharged
Diesel Engine
performance requirement for the generator. Reference Table
1 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 RPM or speed
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 5) as a guide
for selecting proper extension cable size.
Open-Delta
" excitation system. The open delta
fixed ceiling
" and responds
John Deere Model 6068FH275
. This engine is designed to meet every
PAGE 18 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — MAJOR COMPONENTS
Figure 5. Major Components
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DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 19
NOTE PAGE
PAGE 20 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of
the DCA-150USJ
Generator Control Panel
(Figure 6).
1. Main Circuit Breaker – This three-pole, 400A main
breaker is provided to protect the the
Terminal Lugs
from overload.
U,V, and W Output
2. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
3. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
4. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
Located behind the generator control panel is the
Control Box
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
■■
■
Automatic Voltage Regulator
■■
■■
■
Current Transformer
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer
■■
■■
■
Starter Relay
■■
■■
■
Engine Controller (Electronically Controlled)
■■
■■
■
Voltage Selector Switch
■■
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
NOTE
only.
5. AC Voltmeter – Indicates the output voltage present at
the
U,V, and W Output Terminal Lugs
.
In the event of a short circuit or over current condition, it will
6. Voltmeter Change-Over Switch – This switch allows
automatically trip the 60 amp main breaker.
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
To restore power to the
reset
button on the overcurrent relay and place the
circuit breaker in the
7. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.
Generator
. This box contains some of the necessary
Remember the
relay
monitors the current
flowing from the
Output Terminal Lugs
overcurrent
U,V, and W
to the
load.
Output Terminal Panel
, press the
main
closed
position (ON).
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 21
DCA-150USJ — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
PAGE 22 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-150USJ
1. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. 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.
4. Water Temperature Gauge – During normal operation
this gauge be should read between 180° and 221°F.
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 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.
8. Pre-Heat Lamp – As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine.
When the lamp turns off, the engine has been preheated
and will start automatically.
9. Fuel Leak Detected Alarm Lamp – This lamp will
illuminate when a leak in the fuel tank containment
enclosure is detected.
10. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical row
of status LED's (inset), that when
lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has been
detected the engine controller will
evaluate the fault and all major
faults will shutdown the generator.
Engine Operating Panel
(Figure 7).
During
engine for 10 seconds before disengaging. If the engine does
not engage (start) by the third attempt, the engine will be
shutdown by the engine controller’s
mode. If the engine engages at a speed (RPM's) that is not
safe, the controller will shutdown the engine by initializing
the
Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, and
loss of magnetic pickup. These conditions can be observed
by monitoring the LED status indicators on the front of the
controller module.
A. MPEC Control Switch – This switch controls the
B. Low Oil Pressure – Indicates the engine pressure has
C. High Coolant Temperature – Indicates the engine
D. Overcrank Shutdown – Indicates the unit has
E. Overspeed Shutdown – Indicates the engine is running
F. Engine Running – Indicates that engine is running at
cranking cycle
Over Speed Protection
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the AUTO position.
fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a
will occur.
temperature has exceeded 239°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a
major
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration. This is considered a
fault and shutdown will occur.
at an unsafe speed. This is considered a
and shutdown will occur.
a safe operating speed and at nominal levels.
, The MPEC will attempt to crank the
Over Crank Protection
mode.
major
fault and shutdown will occur.
fault and shutdown
major
major
fault
1
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 23
DCA-150USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The
Output Terminal 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
Output Terminal Familiarization
The “
Output Terminal Panel
following:
■■
■
Three (3) 120/240V output receptacles @ 50 amp
■■
lugs.
■■
■
Three (3) Circuit Breakers @ 50 amps
■■
■■
Two (2) 120V GFCI receptacles @ 20 amp
■
■■
■■
Two (2) GFCI Circuit Breakers @ 20 amps
■
■■
.
■■
■
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
■■
NOTE
Terminal legs “O” and “Ground”
are considered
bonded grounds
” (Figure 8) is provided with the
Figure 8. Output Terminal Panel
PAGE 24 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
DCA-150USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
any
receptacles can be accessed in
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
being tripped. Pressing the
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
reset
button resets the GFCI receptacle after
voltage selector switch
Test Button
(See Figure 9) in
Each auxilliary 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
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Removing the Plastic Face Plate (Hard Wire Hookup Panel)
The
Output Terminal Lugs
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
.
voltage regulator control knob
increase
decrease
Figure 11. Voltage Regulator Control Knob
the voltage, turning the knob counter-
the voltage.
are protected by a plastic face
(Figure 11) on the
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output
terminal panel.These receptacles can
when the voltage selector switch is placed in the
phase 240/120 position.
only
be accessed
single-
Figure 12. Plastic Face Plate (Output Terminal Lugs)
Figure 10. 120/240V Twist-Lock
Auxiliary Receptacles
DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08) — PAGE 25
1
DCA-150USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the
Terminal Lugs
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, 400A
switch ALL circuit breakers to the OFF position prior to
starting the engine.
or the convienience receptacles (Figure 13).
main
circuit breaker is provided. Make sure to
Ouput
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
Selector Switch
DANGER - ELECTROCUTION HAZARDS
Voltage
(Figure 15).
Figure 15. Blower Fan Fuse
Figure 13. Connecting Loads
Over Current Relay
An
over current relay
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
rent relay must be pressed. The over current relay is located in the control box.
(Figure 14) is connected to the main
reset button
on the over cur-
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
bodily harm
completely off before attempting to replace
or handle this fuse.
electrocution
. ALWAYS turn the unit
and
severe
Figure 14. Over Current Relay
PAGE 26 — DCA-150USJ — OPERATION AND PARTS MANUAL — REV. #1 (01/15/08)
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