Multiquip DCA220SSCU4i, DCA220SSCU User Manual
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA220SSCU
MODEL DCA220SSCU4i
60Hz GENERATOR
(CUMMINS QSB7-G6 DIESEL ENGINE)
PARTS LIST NO. M4870300204
Revision #0 (10/25/12)
To find 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 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
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 Traffic 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 finds
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 1-888327-4236 (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.
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 3
TABLE OF CONTENTS
DCA220SSCU/SSCU4i
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Safety Information ..............................................6-11
Specifications ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................14-15
General Information ............................................... 16
Major Components ................................................ 17
Engine Control Unit (ECU) .................................... 18
Engine/Generator Control Panel............................ 19
Output Terminal Panel Familiarization .............. 20-22
Load Application .................................................... 23
Generator Outputs ................................................. 24
Generator Outputs/Gauge Reading ....................... 25
Output Terminal Panel Connections ................. 26-27
Inspection/Setup ............................................... 28-31
Generator Start-Up Procedure (Manual) .......... 32-33
Generator Start-Up Procedure (Auto Mode) .......... 34
Generator Shut-Down Procedures ........................ 35
Maintenance ..................................................... 36-41
Trailer Maintenance .......................................... 42-45
TTrailer Wiring Diagram ......................................... 46
Generator Wiring Diagram ..................................... 47
Engine Wiring Diagram .......................................... 48
Troubleshooting (Generator) .................................. 49
Troubleshooting Diagnostics ................................. 50
Explanation of Code in Remarks Column.............. 52
Suggested Spare Parts ......................................... 53
Component Drawings
Generator Assembly ......................................... 54-57
Control Panel Assembly ................................... 58-59
Control Box Assembly ...................................... 60-63
Engine And Radiator Assembly ........................ 64-65
Output Terminal Assembly ................................ 66-67
Battery Assembly.............................................. 68-69
Muffler Assembly .............................................. 70-71
Fuel Tank Assembly .......................................... 72-73
Enclosure Assembly ......................................... 74-79
Rubber Seals Assembly ................................. 80-81
Nameplate And Decals Assembly .................... 82-85
Terms And Conditions Of Sale — Parts ................ 86
NOTICE
Specifications are subject to change without notice.
PAGE 4 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
NOTES
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
Potential hazards associated with the operation of this
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
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 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
SAFETY INFORMATION
GENERAL SAFETY
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
Also, know the
and
This information will be invaluable in
emergency or safety devices.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
ensure generator is on level ground before use.
keep the machine in proper running condition.
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
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site.
phone numbers of the nearest ambulance, doctor
fi re department.
the case of an emergency.
GENERATOR SAFETY
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
These devices are int ended for operator safet y.
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS
ALWAYS
Fix damage to machine and replace any broken parts
immediately.
ALWAYS
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 7
ENGINE SAFETY
NOTICE
run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
Wet stacking is a common problem with diesel engines
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
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
applied to relieve the condition. It can reduce the system
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
from the engine exhaust. Spark arresters are qualifi ed
SAFETY INFORMATION
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT pl a c e ha nds 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.
NEVER
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
which are operated for extended periods with light or
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.
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
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
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.
PAGE 8 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
to prevent accidental discharge of sparks or fl ames
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.
FUEL SAFETY
DANGER
Make sure the hitch and coupling of the towing vehicle
NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Trailer tires should be infl ated to 50 psi cold.
safety
attach trailer’s safety chains to towing
make sure the vehicle and trailer directional,
unless
posted otherwise. Recommended off-road towing is not to
Avoid sudden stops and starts. This can cause skidding,
Trailer should be adjusted to a level position at all times
rolling
underneath the trailer’s bumper
Use the trailer’s swivel jack to adjust the trailer height to
SAFETY INFORMATION
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
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 sm oke around or ne a r th e
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
Check with your local county or state safety
towing regulations, in addition to meeting
Depar tment of Transpor tation (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
CAUTION
ALWAYS inspect the hitch and coupling for wear.
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
chain.
ALWAYS properly
vehicle.
ALWAYS
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
exceed 15 MPH or less depending on type of terrain.
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent
while parked.
Place support blocks
to prevent tipping while parked.
a level position while parked.
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 9
ELECTRICAL SAFETY
DANGER
Make sure power cables are securely connected to the
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
make sure that electrical circuits are properly
Severe injury or death by
can result from operating an ungrounded
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
SAFETY INFORMATION
generator’s output receptacles. Incorrect connections
may cause elect r ical shock and damage to the
generator.
NOTICE
ALWAYS
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
receptacl es 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.
Chart in this manual.
Grounding Safety
DANGER
ALWAYS
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator.
electrocution
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 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
SAFETY INFORMATION
BATTERY SAFETY
ENVIRONMENTAL SAFETY
pour waste, oil or fuel directly onto the ground,
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.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
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
down a drain or into any water source.
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.
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 11
Model
Type
Armature Connection Star with Neutral
Phase
Standby Output
Prime Output
3Ø Voltage (L-L/L-N)
Voltage Change-Over Bd. at 3Ø 240/139
3Ø Voltage (L-L/L-N)
Voltage Change-Over Bd. at 3Ø 480/277
1Ø Voltage (L-L/L-N)
Voltage Change-Over Bd. at 1Ø 240/120
Power Factor
Frequency
Speed
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Wet Weight
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Lubricating Type Oil
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
1
Includes engine and radiator hoses
2
Includes filters
Table 1. Generator Specifications
DCA220SSCU/ DCA220SSCU4i
Revolving field, self ventilated,
open protected type synchronous generator
194 kW (242 kVA)
176 kW (220 kVA)
208Y/120, 220Y/127, 240Y/139
416Y/240, 440Y/254, 480Y/277
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
6,636 lbs. (3,010 kg)
7,496 lbs. (3,400 kg)
Table 2. Engine Specifications
Cummins QSB7-G6 EPA Interim Tier 4 Certified
4 cycle, water-cooled, direct injection, turbo-charged
air cooled and EGR
4.21 in. x 4.88 in. (107 mm x 124 mm)
409 cu. in. (6.7 liter)
282 HP at 1800 rpm
11.4 gal. (43.0 liters)
4.6 gal. (17.5 liters)
API service class CJ-4 SAE 15W-40
#2 Diesel Fuel (Ultra low sulfur diesel fuel only)
100 gal. (380 liters)
12.4 gal. (46.8 L)/hr at full load 9.5 gal. (36.0 L)/hr at 3/4 load
6.9 gal. (26.0 L)/hr at 1/2 load 4.4 gal. (16.8 L)/hr at 1/4 load
27 (CCA 0°F 800A) X 2
SPECIFICATIONS
3
240/120
0.8
60 Hz
1800 rpm
6 cylinders
Electric
1
2
PAGE 12 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
DIMENSIONS
A E
B
C
D
MAXIMUM
LIFTING
POINT
14,050 lbs.
(6,373 kg)
220
TOP VIEW
SIDE VIEW
F
FRONT VIEW
Figure 1. Dimensions
G
Reference
Letter
A 31.10 in. (790 mm) E 41.33 in. (1,050 mm.)
B 31.10 in. (790 mm) F 137.79 in. (3,500 mm)
C 41.33 in. (1,050 mm) G 68.89 in. (1,750 mm)
D 41.33 in. (1,050 mm) H 51.18 in. (1,300 mm)
H
Dimension in. (mm) Reference Letter Dimension in. (mm)
Table 3. Dimensions
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 13
INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
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 shor t circuits and
grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground (Figure 2).
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
INDOOR INSTALLATION
Exhaust gases from diesel engines are extrem ely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
NOTICE
This generator has a permanent bonding conductor
between the generator stator windings and the frame.
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 15
GENERAL INFORMATION
GENERATOR
This generator (Figure 3) is designed as a high quality
portable (requires a trailer for transport) power source for
telecom sites, lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
OPERATING PANEL
The “Operating Panel” is provided with the following:
ECU Controller
Gauge Unit Assembly
• Oil Pressure Gauge
• Water Temperature Gauge
• Charging Voltmeter
• Fuel Gauge
• Tachometer
Panel Light/Panel Light Switch
Hour Check Button
Auto Start/Stop Switch
Engine Speed Switch
Emergency Stop Button
Water Temperature Gauge
CONTROL PANEL
The “Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 600 amp Main Circuit Breaker
“Control Box” (located behind Control Panel)
• Automatic Voltage Regulator
• Current Transformer
• Over-Current Relay
• Starter Relay
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Eight output terminal lugs (3Ø power)
Ground lug
Battery Charger (Optional)
Jacket Water Heater (Optional)
OPEN DELTA EXCITATION SYSTEM
Each generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
ENGINE
This generator is powered by a 6 cylinder, 4-cycle water
cooled, direct injection, turbocharged, air cooled Cummins
QSB7-G6
meet every performance requirement for the generator.
Reference Table 2 for engine specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
diesel engine. This engine is designed to
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
MAJOR COMPONENTS
220
U
V
W
O
GND
Denyo
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
PSI
OILPRESS
0
25
50
75
100
°F
WATERTEMP
100
140
180
220
260
VOLTS
BATTERY
6
12
18
24
30
FUEL
E
½
F
RPMX10
SPEED
0
120
150
180
210
60
Engine Started
Shutdown
Pre-Alarm
Series 800 Controller
Alarm
Acknowledge
Screen
Change
Program/
Exit
Option
ECU
1
2
3
4
56
7
8
11
9
10
220
Table 4. Generator Major Components
ITEM NO. DESCRIPTION
1 Muffler Assembly
2 Enclosure Assembly
3 Generator Assembly
4 Battery Assembly
5 Engine Assembly
6 Fuel Tank Assembly
7 Output Terminal Assembly
8 Circuit Breaker Assembly
9 Auto Start/Stop Controller Assembly
10 Gauge Unit Assembly
11 Operating Panel Assembly
Figure 3. Major Components
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 17
ENGINE CONTROL UNIT (ECU)
1
ECU
Series 800 Controller
Alarm
Screen
Acknowledge
Change
E F
Engine Started
A
Program
Option
Exit
G
H
Shutdown
Pre-Alarm
B
C
D
Figure 4. Engine Control Unit (ECU)
The definitions below describe the controls and functions
of the Engine Control Unit (Figure 4).
1. ECU Controller — This auto start/stop controller
displ ays th e p a r a meter s a n d the diagn o s t ic
troubleshooting messages of the engine, and controls
DPF regeneration.
A. ECU Display Screen — Engine fault diagnostic
messages are shown on this LCD display. screen
B. Engine Started Lamp — This lamp when lit
indicates engine is operating normally.
C. Engine Shutdown Lamp — When an engine
failure has occured this lamp will blink. Indicating
the engine has been shutdown. The diagnostic
fault message will be displayed on the LCD screen.
D. Pre Alarm Lamp — When an engine failure has
occured this lamp will blink. Indicating a pre-fault
engine condition and the possibility of engine
shutdown.The diagnostic fault message will be
displayed on the LCD screen
0
ECU
50
25
PSI
OILPRESS
Alarm
Acknowledge
180
75
100
Series 800 Controller
Screen
Change
18
140
12
220
24
°F
VOLTS
100
6
260
30
WATERTEMP
BATTERY
½
150
120
180
60
°F
RPMX10
E
0
F
210
FUEL
SPEED
Engine Started
Shutdown
Pre-Alarm
Program
Option
Exit
INCREASE DECREASE
V
U
W
OFF
V-W
W-U
U-V
OFF
E. Alarm Acknowledge Button — When the engine
experiences a fault, the "Pre Alarm Lamp" or the
"Shutdown Lamp" will start blinking. Pushing this
button will confirm the fault message and the
blinking lamp will change to a solid lamp display.
The fault message will be displayed on the screen.
When multiple engine faults occur, the lamp will
continue blnking until all fault messages are
confirmed. The blinking lamp will change to a solid
lamp display all current confirmed fault messages
will scrool across the screen.
F. Screen Change Button — When this button is
pushed during operation, the screen will cycle
through each parameter screen.
G. Option Button — This button is not active. Do
not use.
H. Program/Exit Button — Pushing this button
allows the DPF Force Regen and diagnostic code
to be confirmed.
PAGE 18 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
0
7
4
5
6
8
9
10
11
13
12
2
3
14
50
25
PSI
OIL PRESS
ENGINE/GENERATOR CONTROL PANEL
1
50
180
25
A
75
140
100
100
D
E
180
°F
WATERTEMP
½
°F
FUEL
220
B C
18
12
VOLTS
6
260
BATTERY
E
150
120
60
RPMX10
0
F
SPEED
24
30
180
210
0
ECU
PSI
OILPRESS
Alarm
Acknowledge
75
100
Series 800 Controller
Screen
Change
Figure 5. Gauge Unit Assembly
18
140
12
220
24
°F
VOLTS
100
6
260
30
WATERTEMP
BATTERY
½
150
120
180
60
°F
RPMX10
E
0
210
F
FUEL
SPEED
Engine Started
Shutdown
Pre-Alarm
Program
Option
Exit
INCREASE DECREASE
V
U
W
OFF
V-W
W-U
U-V
OFF
The definitions below describe the controls and functions
of the Engine/Generator Control Panel (Figure 5).
1. Gauge Unit Assembly — This assembly houses
the various engine monitoring gauges. These gauges
indicate: oil pressure, water temperature, charging
voltmeter, fuel and engine speed RPM (tachometer).
A. Oil Pressure Gauge — During normal operation
this gauge be should read between 35 to 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.
B. Water Temperature Gauge — During normal
operation this gauge be should read between 180°
and 225°F (82°~107°C).
C. Charging Voltmeter Gauge — During normal
operation this gauge indicate minimum 26 VDC
D. Fuel Gauge — Indicates amount of diesel fuel
available.
5. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
6. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
7. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
8. Ammeter Change-Over Switch — This switch allows
the AC ammeter to indicate the current flowing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
9. Voltmeter Change-Over Switch — This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
10. Emergency Stop Button — Push this button inward
to stop the engine in the event of an emergency. DO
NOT use this button as a means of stopping the engine.
E. Tachometer — Indicates engine speed in RPM’s
for 60 Hz operation. This meter should indicate
1800 RPM’s when the rated load is applied. .
2. Panel Light — For operation at night, panel light
illuminates control panel for ease of reading meters
and gauges. Make sure oanel light switch is in the OFF
position when light is not in use.
3. Panel Light Switch — When activated will turn on
control panel light.
4. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 19
11. Engine Speed Switch — This switch controls the
speed of the engine (low/high).
12. Auto/Start Switch — This switch selects either manual
or automatic operation . Center position is OFF (reset).
13. Hour Check Button — With the engine stopped, press
and hold ths button. The total running hours, fuel level,
and battery voltage will be displayed.
14. Main Circuit Breaker — This three-pole, 600 amp
main breaker is provided to protect the U,V, and W
Output Terminal Lugs from overload.
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
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 7) is provided with
the following:
Three (3) 240/139V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
1Ø AND 3Ø,
480 -120 VAC
OUTPUT TERMINALS
V
U
BLACK RED BLUE WHITE GREEN
NEUTRAL
TERMINAL
O
W
CIRCUIT BREAKERS
FOR GFCI RECEPTACLES
W
TWIST-LOCK
CS-6369
GROUND
TERMINAL
HARD WIRE
HOOKUP PANEL
Y
X
AUX. POWER RECEPTACLES
240/139V, 50 AMPS
Figure 6. Output Terminal Panel
CIRCUIT BREAKERS
FOR CS-6369 TWIST
LOCK RECEPTACLES
120 VAC, 20 AMP
GFCI RECEPTACLES
PAGE 20 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
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. These
receptacles can be accessed in any voltage change-over
board configuration. 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 7) 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 9) 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 9. Voltage Regulator Control Knob
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 240/139V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage change-over board is configured for
single-phase 240/120 application
Figure 8. 240/139V Twist-Lock Auxiliary
Receptacles
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 10).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3-pole,
600A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 10. Connecting Loads
Over Current Relay
An over current relay (Figure 11) 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 11. Over Current Relay
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 600 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 22 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
THREE PHASE LOAD
When calculating the power requirements for 3-phase
power use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
Table 5. Power Factor By Load
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
Electronic devices, communication
equipment
1.0
Common power tools 0.8
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
Whe n con nect ing a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 23
GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
A wide range of voltages are available to supply voltage
for many different applications. Voltages are selected by
applying jumpers (6) to the voltage change-over board
(Figure 12). To obtain some of the voltages as listed in
Table 7 (see below) will require a fine adjustment using
the voltage regulator (VR) control knob located on the
control panel.
Voltage Change-Over Board
The voltage change-over board (Figure 12) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
Maximum Amps
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.
Table 8. Generator Maximum Amps
Model
Rated Voltage Maximum Amps
Single Phase 120 Volt 488.9 amps (4 wire)
Single Phase 240 Volt 244.4 amps (4 wire)
Three Phase 240 Volt 529 amps
Three Phase 480 Volt 264 amps
DCA220SSCU/
DCA220SSCU4i
Figure 12. Voltage Change-Over Board
CAUTION
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
Table 7. Voltages Available
UVWO Output
Terminal Lugs
Line-Line
3Ø
1Ø Line-Neutral 120V 127V 139V 240V 254V 277V
1Ø Line-Neutral/
Line-Line
Voltage Change-Over Board
3-Phase 240/139V Position
208V 220V 240V 416V 440V 480V
Voltage Change-Over Board Single-Phase 240/120V Position
120V
Line-Neutral
N/A N/A
Voltage Change-Over Board
3-Phase 480/270V Position
240V
Line-Line
N/A N/A
PAGE 24 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, configure the
Voltage Change-Over Board (Figure 13) which produces
the desired output voltage.
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 16)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 17). This process can be repeated for
terminals V and W.
Figure 16. AC Ammeter
Change-Over Switch
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 17. AC Ammeter
(Amp reading on U Lug)
Figure 13. Voltage Change-Over Board
Ø Position
240/3
AC Voltmeter Gauge Reading
Place the AC Voltmeter Change-Over Switch (Figure 14)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 15).
Figure 14. AC Voltmeter
Change-Over Switch
Figure 15. AC Voltmeter Gauge
(Volt reading on W-U Lug)
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 25
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the placement of the jumpers plates (6) on
the Voltage Change-Over Board and the adjustment of
the Voltage Regulator Control Knob.
Remember the voltage change-over board determines the
range of the output voltage and can be configured in two
different positions that provide 6 different output voltages
at the UVWO output terminals. The generator is shipped
from the factory in the 240V configuration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
3Ø-240V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 240V
operation as shown in Figure 18
3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
Figure 20. Voltage Regulator Knob
1Ø-240V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 18.
2. Connect the load wires to the UVWO terminals as
shown in Figure 21.
Figure 18. Voltage Change-Over Board 240V
Configuration
2. Connect the load wires to the UVWO terminals as
shown in Figure 19.
Figure 19. UVWO Terminal Lugs
Figure 21. UVWO Terminal Lugs 1Ø-240V
Connections
1Ø-120V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 18.
2. Adjust voltage regulator knob (Figure 20) for an output
of 208V to obtain 120V at the UVWO terminals.
3. Connect the load wires to the UVWO terminals as
shown in Figure 22.
Figure 22. UVWO Terminal Lugs 1Ø-120V
Connections
PAGE 26 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 480V
operation as shown in Figure 23. This configuration
uses 6 jumper plates in 3 different positions. Remember
there are 2 jumper plates at every position. Every
jumper plate must be used.
Figure 23. Voltage Change-Over Board 480V
Configuration
2. Connect the load wires to the UVWO terminals as
shown in Figure 24.
1Ø-480V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
Figure 25. UVWO Terminal Lugs 1Ø-480V
Connections
1Ø-277V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 23.
Figure 24. UVWO Terminal Lugs 3Ø-480V
Connections
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fire.
2. Connect the load wires to the UVWO terminals as
shown in Figure 26.
Figure 26. UVWO Terminal Lugs 1Ø-277V
Connections
DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 27
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