Multiquip DCA-36SPX User Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-36SPX

60 Hz GENERATOR

(PARTS LIST NO. B2871300404 S/N 3798495~)

Revision #1 (04/14/10)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 3

MQ POWER DCA-36SPXMQ POWER DCA-36SPX

MQ POWER DCA-36SPX

MQ POWER DCA-36SPXMQ POWER DCA-36SPX

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

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 ........................................... 10-15

Generator Decals....................................................... 16-17

Installation ................................................................. 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

Gauge Reading ............................................................... 30

Pre-Setup .................................................................. 31-34

Generator Start-up Procedure (Manual) ..................... 35-36

Generator Start-up Procedure (Auto Mode) .................... 37

Generator Shut-Down Procedure .................................... 38

Maintenance (Engine) ................................................ 39-41

Maintenance (Trailer) ................................................. 42-45

Trailer Wiring Diagram .....................................................46

Generator Wiring Diagram ............................................... 47

Engine Wiring Diagram ................................................... 48

Troubleshooting (Engine) ........................................... 49-50

Troubleshooting (Generator) ............................................ 51

Engine Controller Troubleshooting ................................... 52

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 56-57

Engine Operating Panel Assembly ............................ 58-59

Control Box Assembly ............................................... 60-61

Engine and Radiator Assembly ................................. 62-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure Assembly ................................................. 74-77

Rubber Seals Assembly ............................................ 78-79

Nameplate and Decals .............................................. 80-81

Terms and Condition of Sale — Parts ............................ 82

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

N View Parts Diagrams

N Order Parts N Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Par ts

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 your 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.*

Note: Discounts Are Subject To Change

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R Quantity, Part Number and Description of Each Part

www.mqpower.com

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 5

When ordering parts, please supply:

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Truck  N Ground N Next Day N Second/Third Day

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA-36SPX — SPECIFICATIONS

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snoitacificepSenignE.2elbaT

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gnitratS

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PAGE 6 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — DIMENSIONS (TOP, SIDE AND FRONT)

TOP VIEW

Figure 1. Dimensions

SIDE VIEW

FRONT VIEW

Denyo

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm837(.ni1.92F ).mm009,1(.ni8.47

B).mm837(

C).mm516(.ni2.42H ).mm009(.ni34.53

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).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

D).mm077(.ni3.03

E).mm536(.ni0.52

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 7

DCA-36SPX — 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-36SPX

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

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

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-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

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-36SPX — 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 (MPEC) in the OFF/RESET position when the generator 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

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

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

sufficient 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 turbocharges, and reduce the operating performance. In order for a diesel engine to operate at peak efficiency 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 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.

CAUTION - ENGINE LOAD (WET-STACKING)

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 9

DCA-36SPX — RULES FOR SAFE OPERATION

DANGEROUS

GAS FUMES

Denyo

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

or even

DEATH

! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the

DCA-36SPX Whisperwatt™ AC Generator.

General Safety:

■

DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generators.

■

The engine section of this generators requires an adequate free flow of cooling air. any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generators or engine and may cause injury to people. Remember the generator's engine gives off carbon monoxide gas.

NEVER

DEADLY

operate the generators in

■

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.

■

ALWAYS wear proper respiratory (mask), hearing and eye protection equipment when operating the generator.

■

Whenever necessary, replace nameplate, operation and

■

safety decals when they become difficult read.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

ALWAYS refuel in a well-ventilated area, away from sparks and open flames.

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT

smoke

around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

bodily

harm or even death.

NEVER disconnect any

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.

"emergency or safety devices"

PAGE 10 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — RULES FOR SAFE OPERATION

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generators.

NEVER leave the generator unattended, turn off engine when unattended.

Unauthorized equipment modifications will void all warranties.

ALWAYS ensure generator is on level ground before use.

DO NOT place hands or fingers inside generators engine

compartment when engine is running.

NEVER run engine without air cleaner. Severe engine damage

may occur.

NEVER change or adjust the engine speed which has been

set at the factory prior to shipping.

Power Cord Safety

NEVER let power cables or cords

NEVER

is being transfer to a load.

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 power or extension cord has been selected for the job See Table 4.

stand in water

while AC power from the generators

lay in wate

Grounding Safety

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

death!

ungrounded generator.

ALWAYS make sure the generators are properly grounded to a suitable earth ground (GROUND ROD). See installation in this manual.

per the

by electrocution can result from operating an

National Electrical Code

(NEC) and

injury

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

High Temperatures – Always stop engine and allow the engine to cool before adding fuel, oil or performing service and maintenance

hot!

functions. Contact with cause serious burns.

Keep the machinery in proper running condition.

Fix damage to the machine immediately and replace any broken parts immediately.

ALWAYS replace any worn or damaged warning decals.

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 un-authorized personnel.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. performing maintenance on the generator.

Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters.

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.

Turn all circuit breakers OFF before

components can

ALWAYS allow the machine a proper amount of time to

cool before servicing.

ALWAYS service air cleaner frequently to prevent engine malfunction.

ALWAYS disconnect the

NEGATIVE battery terminal

before performing service on the generator.

Follow all battery safety guidelines listed in this manual when handleing or servicing the generator.

NEVER use

gas piping

as an electrical ground.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 11

DCA-36SPX — RULES FOR SAFE OPERATION

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the

coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

■

Engine Oil Drain Plug - Removing the engine oil drain

plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Battery Safety

Use the following guidelines when handling the battery:

■

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

wear safety

severe injury

DEATH:

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.

clothing or skin

EYES

, rinse skin or clothing

, rinse eyes immediately with

PAGE 12 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — RULES FOR SAFE OPERATION

ACCIRCUIT BREAKER

OFF

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

OFF

120

20A

120V

OFF

GA-2.9R

DANGERDANGER

DANGER

DANGERDANGER

During operation of this generation, there exists the possibility of

electrical shock or burn

cause

severe bodily harm

DEATH!

To avoid these hazards:

NEVER use

Electrocution HazardsElectrocution Hazards

Electrocution Hazards

Electrocution HazardsElectrocution Hazards

electrocution

, which can

or even

damaged

worn

cables when connecting

Engine exhaust gases contain

poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output receptacles, incorrect connections may cause damage to the generators and electrical shock.

NEVER grab or touch a live power cord with wet hands, the possibility exist of electrical shock, electrocution, and even

death!

DANGERDANGER

DANGER

DANGERDANGER

Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards

Lethal Exhaust Gas Hazards

Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards

DANGER

Using a generator indoors .CAN KILL YOU IN MINUTES

Generator exhaust contains carbon monoxide. This is a posion you cannot see or smell

20A

120

2900

GA-2.9R

ACCIRCUIT

2900

GA-2.9R

ACCIRCUIT BREAKER

NEVER use inside a home or garage, even if doors and windows are open

Avoid other generator hazards.

2900

GA-2.9R

120V

ACCIRCUIT BREAKER

Only use OUTSIDE and far away from windows, doors, and vents.

BREAKER

OFF

.READ MANUAL BEFORE USE

Emergencies

NEVER insert any objects into

the output receptacles during

ALWAYS know the location of the

nearest

operation. This is extremely dangerous. ALWAYS turn-off the generators and place all circuit breakers in the “OFF” position when contact with the output receptacles is required. There exist the possibility of

electrocution,

ALWAYS know the location of the nearest

first aid kit

electrical shock or burn, which can cause severe bodily harm or even death

Backfeed to a utility system can cause

electrocution

NEVER connect the generators to a

building's electrical system without a transfer switch or other approved device. All installations should be performed by

licensed electrician

a with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn causing serious injury or even death!

and or property damage.

in accordance

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

fire extinguisher

always

know the location of the

keep a phone on the job site

and

fire department

. This

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 13

DCA-36SPX — RULES FOR SAFE OPERATION

■

If your generator is trailer mounted, please read the towing and safety requirements listed below.

Towing and Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - 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.

■

Drain fuel from generator fuel tank before towing.

■

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.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

DOT Requirements include the following:



Connect and test electric brake operation.



Secure portable power cables in cable tray with tie wraps.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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.

Trailer tires should be inflated to 50 psi cold.

PAGE 14 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

NOTE

For more saftey tips, see the trailer saftey guidelines section in this manual.

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 15

DCA-36SPX — GENERATOR DECALS

The DCA-36SPX generator is equipped with a number of safety decals (Figures 2 and 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 16 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 17

DCA-36SPX — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 18 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — 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 mm2) or larger.

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 aminimum of 8 ft. into the ground.

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.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 19

DCA-36SPX — GENERAL INFORMATION

DCA-36SPX Whisperwatt™ Series Familiarization Generator

The MQ Power Model DCA-36SPX is a 36 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:

Open Delta Excitation System

The DCA-36SPX generator is equipped with the state of the art "

Open-Delta

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.

■■

Tachometer

■

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Panel Light/Panel Light Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

■■

■

Pre-Heat Lamp

■■

■

Pre-Heat Button

■■

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

■■

■

Voltage Regulator

■■

■

3-Pole, 150 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 (Computer 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, (for CS-6369), 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Four output terminal lugs (1Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

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-36SPX is powered by a 4 cylinder, water cooled, direct injection, engine is designed to meet every 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 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.

" excitation system. The open delta system

fixed ceiling

Isuzu Model BB-4JG1T diesel engine

" and responds

. This

PAGE 20 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — MAJOR COMPONENTS

AUTO

MANUAL

OFF/RESET

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DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 21

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PAGE 22 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — GENERATOR CONTROL PANEL

INCREASE

DECREASE

OFF

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-36SPX

Generator Control Panel

(Figure 6).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the load

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

3. AC Voltmeter – Indicates the output voltage present at

the

U,O, and V Output Terminal Lugs

4. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

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:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

■

Single Phase Circuit Breaker

■■

Generator

. This box contains some of the necessary

5. 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.

6. Main Circuit Breaker – This three-pole, 150A main

breaker is provided to protect the the

Terminal Lugs

from overload.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 23

U,O, and V Output

NOTE

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,O and V

to the

load.

In the event of a short circuit or over current condition, it will automatically trip the 90 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

Output Terminal Panel

closed

position (ON).

, press the

main

DCA-36SPX — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 24 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

DCA-36SPX — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-36SPX

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 73 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.

4. Water Temperature Gauge – During normal operation

this gauge should read between 180° and 221°F (82° ~105°C)

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. Fuel Filter Water Level Alarm Lamp– This lamp will

illuminate when an excessive amount of water has accumulated in fuel filter. Drain water in the strainer immediately if this lamp is on.

9. 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. During

cycle

crank the engine for 10 seconds before disengaging.

Engine Operating Panel

(Figure 7).

cranking

, The MPEC will attempt to

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s

Crank Protection

(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, low coolant level, 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

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 an automatic transfer switch (isolation), place the switch in the AUTO position. In this position, should an outage occur, the automatic transfer switch (ATS) will start the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

B. Low Oil Pressure – Indicates the engine pressure has

fallen below 14 psi (97 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 221°F. (105°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

D. Overcrank Shutdown – Indicates the unit has

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.

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

Over

mode. If the engine engages at a speed

Over Speed Protection

major

fault.

mode.

fault.

major

fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 25

DCA-36SPX — 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:

■■

■

Two 120/240V output receptacles (CS-6369), 50A

■■

lugs.

■■

■

Two auxilliary circuit breakers, (for CS-6369), 50A

■■

Two 120V GFCI receptacles @ 20 amp

■

■■

Two GFCI circuit breakers @ 20 amps

■

■■

■

Four Output Terminal Lugs ( U, O, V and Ground)

SINGLE PHASE

240 -120 VAC

OUTPUT TERMINALS

BLACK

WHITE

RED

■■

GROUND

TERMINAL

GREEN

” (Figure 8) is provided with the

HARD WIRE

HOOKUP PANEL

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

TWIST-LOCK

MQ POWER

ACCESS DOOR

LIFT TO OPEN

CS-6369

Figure 8. Output Terminal Panel

PAGE 26 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

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