Multiquip DCA20SPXU2D User Manual
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA20SPXU2
DIGITAL CONTROLLER
60HZ GENERATOR
(ISUZU BV-4LE2 DIESEL ENGINE)
PARTS LIST NO. M1873300004
Revision #1 (03/25/11)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffi c Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
fi nds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 3
TABLE OF CONTENTS
DCA20SPXU2 60 Hz Generator
With Digital Controller
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ............................................................. 14
Installation ............................................................. 15
General Information ............................................... 16
Major Components ................................................ 17
Control Panel ......................................................... 18
Digital Controller Panel .......................................... 19
Lcd Display/Generator Control Box ....................... 20
Output Terminal Panel Familiarization .............. 21-23
Load Application/Generator Output ....................... 24
Output Terminal Panel Connections ...................... 25
Inspection/Setup ............................................... 26-29
Generator Start-Up Procedure (Manual) .............. 30
Generator Start-Up Procedure (Auto) ................... 31
Generator Shut-Down Procedures ........................ 32
Maintenance ..................................................... 33-36
Trailer Maintenance .......................................... 37-40
Trailer Wiring Diagram ........................................... 41
Generator Wiring Diagram ..................................... 42
Engine Wiring Diagram .......................................... 43
Troubleshooting (Generator) .................................. 44
Protective Devices ................................................. 45
Explanation Of Code In Remarks Column............. 46
Suggested Spare Parts ......................................... 47
Component Drawings
Generator Assembly ......................................... 48-49
Control Box Assembly. ...................................... 50-51
Engine And Radiator Assembly ........................ 52-55
Output Terminal Assembly ................................ 56-57
Battery Assembly.............................................. 58-59
Muffl er Assembly .............................................. 60-61
Fuel Tank Assembly .......................................... 62-63
Enclosure Assembly ......................................... 64-67
Rubber Seals Assembly ................................... 68-69
Nameplate and Decals Assembly .................... 70-71
Terms And Conditions Of Sale — Parts ................ 72
PAGE 4 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
PARTS ORDERING PROCEDURES
r
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
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 Parts
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)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
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.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fi re department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
PAGE 8 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
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 infl ated 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 properly attach trailer’s safety chains to towing
vehicle.
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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. 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
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) 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.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 11
Model
Type
Armature Connection
Phase
Standby Output
Prime Output
SPECIFICATIONS
Table 1. Generator Specifi cations
DCA-20SPXU2D (Digital)
Revolving fi eld, self ventilated,
open protected type synchronous generator
Series
Single-Phase 3-Wire
22 kW
20 kW
Voltage
Frequency
Speed
Power Factor
Aux. AC Power
Sound Level db (A) full Load
at 23 ft. (7 meters)
Weight (No Fuel)
Weight (Fuel)
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
120/240V
60 Hz
1800 rpm
1.0
Single Phase, 60 Hz
63
1,412 lbs. (640 kg.)
1,563 lbs. (709 kg.)
Table 2. Engine Specifi cations
ISUZU BV-4LE2 Interim Tier 4
4 cycle, water-cooled, direct injection
4 cylinders
3.34 in. x 3.77 in. (85 mm x 96 mm)
133 cu. in. (2,179 cc)
34.3 HP/1800 RPM
Electric
1.74 gal. (6.6 liters)
2.25 gal. (8.5 liters)
#2 Diesel Fuel
17 gal. (65 liters)
1.66 gal. (6.3 L)/hr at full load 1.21 gal. (4.6 L)/hr at 3/4 load
0.85 gal. (3.2 L)/hr at 1/2 load 0.58 gal. (2.2 L)/hr at 1/4 load
12V 53Ah x 1
PAGE 12 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
DIMENSIONS
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
A 21.06 in. (535 mm.) F 72.83 in. (1,850 mm.)
B 21.06 in. (535 mm.) G 39.37 in. (1,000 mm.)
C 24.21 in. (615 mm.) H 29.53 in. (750 mm.)
D 26.38 in. (670 mm.)
E 25.00 in. (635 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 13
INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
INSTALLATION
OUTDOOR INSTALLATION
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifi es that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2).
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
INDOOR INSTALLATION
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
3. NEC article 250-52(c) specifi es that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 15
GENERAL INFORMATION
GENERATOR
This generator (Figure 3) is 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.
CONTROL PANEL
Digital Controller (monitors the following:
• Oil Pressure
• Fuel Level
• Battery Voltage
• Water Temperature
• Output Voltage
• Amps (Load)
• Frequency (Hz)
Panel Light
Panel Light Switch
Control Power Switch
3-Pole, 90 amp Main Circuit Breaker
“Control Box” (located behind the Control Panel)
• Engine Controller
• Automatic Voltage Regulator (AVR)
• Current Transformer
• Over-Current Relay
• Starter Relay
• 3-pole, 90 amp Main Circuit Breaker
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
Four output terminal lugs (1Ø power)
OPEN DELTA EXCITATION SYSTEM
This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectifi ed 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 confi guration 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 “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
This generator is powered by a 4 cylinder, water cooled,
direct injection, Isuzu Model BV-4LE2 diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM (OPTION)
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
MAJOR COMPONENTS
Table 4. Generator Major Components
ITEM NO. DESCRIPTION
1 Output Terminal Assembly
2 Auxiliary Receptacles Assembly
3 Muffl er Assembly
4 Air Filter Assembly
5 Battery Assembly
6 Generator Assembly
7 Engine Assembly
8 Fuel Tank Assembly
9 Main Circuit Breaker Assembly
10 Control Panel Assembly
Figure 3. Major Components
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 17
CONTROL PANEL
EDIT
RESET RUN
OFF
AUTO
ALARM
SILENCE
LAMP
TEST
NOT IN
AUTO
ALARM
SUPPLYING
LOAD
5
1 2
INCREASE
DECREASE
SUPPLYING
LOAD
NOT IN
AUTO
4
Figure 4. Control Panel
ALARM
SILENCE
3
LAMP
TEST
The defi nitions below describe the controls and functions
of the Control Panel (Figure 4).
1. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
2.
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.
3. Panel Light Switch — Place switch in the ON position
to activate generator. Place switch in OFF position when
generator is not in use.
4. Control Power Switch — Activates Digital Controller.
5. Main Circuit Breaker—This three-pole, 90A main
breaker is provided to protect the the U,O, and V output
terminal lugs from overload.
PAGE 18 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
DIGITAL CONTROLLER PANEL
1
12
EDIT
11
RESET RUN
Figure 5. Digital Controller Panel
The defi nitions below describe the controls and functions
of the Digital Control Panel (Figure 5).
1. Liquid Crystal Display (LCD) — The LCD serves
as the local information source for metering, alarms,
pre-alarms, and protective functions.
2. Supplying Load Indicator — This green LED lights
when the generator current is greater than the EPS
threshold.
3. Alarm Indicator — This red LED lights continuously
during alarm conditions and fl ashes during pre-alarm
conditions.
4. Alarm Silence — Not used.
5. Lamp Test Pushbutton — Press this pushbutton to
test the illumination of all LCD pixels and LED's on
the Digital Controller.
6. Not in Auto Indicator—This red LED lights when the
Digital Controller is not operating in auto mode.
7. Auto Pushbutton and Mode Indicator — Press
this pushbutton to place the Digital Controller in auto
mode. The green auto LED will light when the auto
mode is active.
8. Off Pushbutton and Mode Indicator — Press this
pushbutton to place the Digital Controller in the off
mode. The red off mode LED will light when the Digital
Controller is in the off mode.
SUPPLYING
LOAD
ALARM
NOT IN
AUTO
10
2
9
3
4
ALARM
SILENCE
OFF
5
LAMP
TEST
AUTO
8
6
7
9. Run Pushbutton and Mode Indicator — Press this
pushbutton to place the Digital Controller in the run
mode. The green run mode LED will light when the
Digital Controller is in the run mode.
10. Reset Pushbutton — Press this pushbutton to cancel
a settings editing session and discard any changes
made to the settings.
11. Edit — Press this pushbutton to start an editing
session and enable changes to the Digital Controller
settings. At the conclusion of an editing session, the
edit pushbutton is pressed again to save the setting
changes.
12. Arrow Pushbuttons — These four pushbuttons are
used to navigate through the display menus and modify
settings.
The left and right arrow buttons are used to navigate
through the display menus and modify settings. The
right-arrow button is pressed to move downward
through the menu levels and the left-arrow is pressed
to move upward.
Within a level, the up-arrow and down-arrow buttons
are used to move among items within the menu level.
Pressing the down-arrow button moves to items lower
in the list.
Pressing the up-arrow button moves to items higher in
the list. During a settings editing session, the up and
down arrow buttons are used to raise and lower the
value of the selected setting.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 19
LCD DISPLAY/GENERATOR CONTROL BOX
The defi nitions below describe the monitoring parameters
of the Digital Control Panel Display(Figure 6).
Figure 6. LCD Display
1. VOLT — Indicates the phase to phase reading at the
output terminals.
2. AMP — Indicates the current flowing to the load
connected at the output terminals.
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
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Via the internet, go to www. basler.com, for more detail
Digital Control Panel operating instructions.
3. PH — Indicates the voltage phase.
4. Hz — Indicates output frequency of the generator.
5. OIL — During normal operation this gauge should read
between 35 ~65 psi. (241~448 kPa). When starting the
generator the oil pressure may read a little higher, but
after the engine warms up the oil pressure should return
to the correct pressure range.
6. FUEL — Indicates the percent of fuel remaining in the
fuel tank.
7. TEMP — During normal operation this gauge be should read
between 167°~203°F (75° ~95°C).
8. BATT — When the engine is running this value should
be greater than 13 VDC.
PAGE 20 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 7) 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.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
SINGLE PHASE
240 -120 VAC
OUTPUT TERMINALS
O
V
RED
BLACK
U
WHITE
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 7) is provided with
the following:
Two 120/240V output receptacles @ 50 amp
Two Circuit Breakers @ 50 amps
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Four Output Terminal Lugs (U, O, V, and Ground)
GROUND
TERMINAL
HARD WIRE
HOOKUP PANEL
GREEN
CIRCUIT BREAKERS
FOR GFCI RECEPTACLES
120 VAC, 20 AMP
GFCI RECEPTACLES
RECEPTACLE
AND
CIRCUIT BREAKER
PANEL
NEUTRAL
TERMINAL
CIRCUIT BREAKERS
FOR CS-6369 TWIST
LOCK RECEPTACLES
AUX. POWER RECEPTACLES
120/240V, 50 AMPS
W
TWIST-LOCK
M
Q
P
O
W
E
CS-6369
R
ACCESS DOOR
LIFT TO OPEN
Y
X
Figure 7. Output Terminal Panel
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
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, O, and V output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 8) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
all three receptacles is dependent on the load requirements
of the output Terminal lugs.
Turn the voltage regulator control knob (Figure 10) on
the control panel to obtain the desired voltage. Turning the
knob clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Figure 10. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire
Hookup Panel)
The output terminal lugs are protected by a plastic face
plate cover (Figure 11). Un-screw the securing bolts and
lift the plastic terminal cover to gain access to the terminal
enclosure.
Figure 8. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are two 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 9) provided on the output
terminal panel..
Figure 9. 120/240V Twist-Lock Auxiliary
Receptacles
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 11. Plastic Face Plate (Output Terminal Lugs)
PAGE 22 — DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the output
terminal lugs or the convenience receptacles (Figure 12).
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,
90A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Over Current Relay
An over current relay (Figure 13) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
Figure 13. Over Current Relay
Figure 12. Connecting Loads
NOTICE
When connecting a load to the generator ALWAYS
make sure the load has an ON/OFF switch. DO NOT
use the circuit breakers on the generator as a method
of turning the load ON and OFF.
DCA20SPXU2D 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 23
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