Multiquip DCA-45SSIU3 User Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-45SSIU3

60 Hz GENERATOR

PARTS LIST NO. M1870300904

Revision #0 (11/30/05)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-45SSIU3 (60 Hz)Whisperwatt™ Generator

. Multiquip Inc. reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 3

DCA-45SSIU3 (60 Hz) — TABLE OF CONTENTS

MQ POWER DCA-45SSIU3 (60 HZ)MQ POWER DCA-45SSIU3 (60 HZ)

MQ POWER DCA-45SSIU3 (60 HZ)

MQ POWER DCA-45SSIU3 (60 HZ)MQ POWER DCA-45SSIU3 (60 HZ)

ISUZU BB4JG1T ENGINE

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 ( Side, Front) .................................................7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ................................................. 20

Engine Operating Panel .................................................. 21

Output Terminal Panel Familiarization ........................ 22-24

Load Application ............................................................. 25

Generator Outputs .......................................................... 26

Gauge Reading ............................................................... 27

Output Terminal Panel Connections ........................... 28-29

Pre Setup .................................................................. 30-33

Generator Start-up Procedure ................................... 34-36

Generator Shut-Down Procedure .................................... 36

Maintenance .............................................................. 37-38

Trailer Maintenance .................................................... 39-42

Trailer Wiring Diagram .....................................................43

Generator Wiring Diagram ............................................... 44

Engine Wiring Diagram ................................................... 45

Generator Troubleshooting .............................................. 46

Engine Troubleshooting ............................................. 47-48

Explanation of Code in Remarks Column ....................... 50

Suggested Spare Parts .................................................. 51

TT™ GENERATT™ GENERA

TT™ GENERA

TT™ GENERATT™ GENERA

TORTOR

TOR

TORTOR

Generator Assembly ............................................ 52-53

Control Box Assembly.......................................... 54-55

Engine & Radiator Assembly ............................... 56-59

Output Terminal Assy. .......................................... 60-61

Engine Operating Panel Assembly...................... 62-63

Battery Assembly ................................................. 64-65

Muffler Assembly ................................................. 66-67

Fuel Tank Assembly ............................................. 68-69

Enclosure Assembly ............................................ 70-73

Rubber Seal Assembly ........................................ 74-75

Nameplate and Decals ........................................ 76-77

Terms and Condition of Sale — Parts ...................... 80

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-45SSIU3 (60 Hz) — SPECIFICATIONS

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PAGE 6 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — DIMENSIONS (TOP, SIDE AND FRONT)

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm077(.ni13.03F ).mm009,1(.ni08.47

B).mm53

C).mm837(.ni50.92H ).mm009(.ni34.53

D).mm516(.ni12.42

E).mm837(.ni50.92

Figure 1. Dimensions

6(.ni00.52G ).mm052,1(.ni12.94

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

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 7

DCA-45SSIU3 (60 Hz) — 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

NOTE

Operation and Parts

has been developed to provide complete instructions for the safe

and efficient operation of the MQ Power

Model DCA-45SSIU3

Manual

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

(60Hz) UltraSilent™ 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-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

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-45SSIU3 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

This generator, other property, or

NOTE

the surrounding environment could be damaged if you do not follow instructions.

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 9

DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

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

The following safety guidelines should always be used when operating the DCA-45SSIU3

or even

DEATH

! This equipment is to be

(60 Hz) Whisperwatt

™

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

ALWAYS check the machine for loosened threads or bolts before starting.

■

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

■

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

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

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

bodily harm or even death.

NEVER

operate the generator in any

■

protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or

drugs or alcohol.

■

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

■

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

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

NEVER run engine without air filter. Severe engine damage may occur.

DO NOT leave the generator running in the unattended.

Refer to the technical questions or information.

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

Isuzu Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

The following safety recommendations should also be followed:

To avoid these hazards: NEVER use damaged or worn cables when connecting

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

Backfeed to a utility system can cause

electrocution

and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 11

DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION

Maintenance Safety

■

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

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handling or servicing the generator.

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

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

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

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

■

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

■

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

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

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

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

DO NOT drop the battery. There

■

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the battery to

■■

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

wear safety

severe injury

clothing or skin

EYES

, rinse skin or clothing

, rinse eyes immediately with

DEATH:

■

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

PAGE 12 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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

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

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

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.

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

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

■

Place while parked.

■

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

■

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

■

Avoid sharp turns.

■

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.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

DOT Requirements include the following:

z z

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

DCA-45SSIU3 (60 Hz) — GENERATOR DECALS

The

DCA-45SSIU3 (60 Hz) Whisperwatt™ Generator

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.

is equipped with a number of safety decals (Figures 2 and 3).

Figure 2. Generator Decals

PAGE 14 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — GENERATOR DECALS

Figure 3. Generator Decals (Continued)

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 15

DCA-45SSIU3 (60 Hz) — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. See Figure 4 for a typical grounding configuration.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 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-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 17

DCA-45SSIU3 (60 Hz) — GENERAL INFORMATION

DCA-45SSIU3 Whisperwatt™ Generator

The MQ Power Model DCA-45SSIU3 is a 36 kW, 60 Hz generator (Figure 5) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

■

Tachometer

■■

■

Water Temperature Gauge

■■

■

Water Temperature Alarm Lamp

■■

Oil Pressure Gauge

■

■■

■

Oil Pressure Alarm Lamp

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Pre-heat Lamp

■■

■

Panel Light/Panel Light Switch

■■

■

Ignition Switch

■■

■

Fuel Filter Water Level Alarm Lamp

■■

Generator Control Panel

The “Generator Control Panel” is provided with the following:

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

3-Pole, 110 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

Familiarization

Open Delta Excitation System

The DCA-45SSIU3 (60 Hz)generator is equipped with the state of the art " 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 " according the demands of the required load.

Open-Delta

" excitation system. The open

fixed ceiling

" and responds

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifier

■■

■

Starter Relay

■■

■

Voltage Selector Switch

■■

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

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

PAGE 18 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — MAJOR COMPONENTS

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DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 19

Figure 5. Major Components

DCA-45SSIU3 (60 Hz) — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the

DCA-45SSIU3 (60 Hz)

Panel

(Figure 6).

Whisperwatt™ Generator Control

1. Main Circuit Breaker – This three-pole, 110A main

breaker is provided to protect the

Terminal Lugs

from overload.

U,V, and W Output

2. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage

3. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz.

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 Rectifier (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

4. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

NOTE

5. AC Voltmeter – Indicates the output voltage present at

the

U,V, and W Output Terminal Lugs

6. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

In the event of a short circuit or over current condition, it will automatically trip the 60 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

7. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

PAGE 20 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

The definitions below describe the controls and functions of the DCA-45SSIU3 (60 Hz) "

1. Panel Light - Normally used in dark places or at night. When activated, panel will illuminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

2. Panel Light Switch- When activated, will turn on control panel light.

3. Oil Pressure Alarm Lamp - Indicates that the oil pressure is too low or high and will shut down the engine.

4. Water Temperature Alarm Lamp - Indicates that the water temperature is outside of normal range and will shut down the engine.

5. Fuel Filter Water Lever Alarm Lamp - Indicates that water level in the fuel level has risen. Drain the water in the fuel filter strainer when this condition occurs.

6. Ignition Switch – Three position switch, stop, operation and start. Insert ignition key to start and stop engine.

Engine Operating Panel

" (Figure 7).

7. Pre-heat Lamp - This indicates when the engine is ready for starting during cold weather operating conditions.

8. Tachometer – Indicates engine speed in RPM’s for 50 Hz operation. This meter should indicate 1500 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

9. Fuel Gauge - Indicates amount of diesel fuel available.

10. 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.

11. Water Temperature Gauge – During normal operation this gauge be should read between 165o F to 203o F.

12. Oil Pressure Gauge – Normal operation should be between 28 ~71 psi (193 ~490 kPa). When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 21

DCA-45SSIU3 (60 Hz) — 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:

■■

■

120/240V output receptacles (3) @ 50 amp

■■

lugs.

■■

■

Circuit Breakers (3) @ 50 amps, 2-pole

■■

120V GFCI receptacles (2) @ 20 amp

■

■■

GFCI Circuit Breaker (2) @ 20 amps, 1-pole

■

■■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■

■■

NOTE

Terminal legs “O” and “Ground”

are considered

bonded grounds

” (Figure 9) is provided with the

Figure 8. Output Terminal Panel

PAGE 22 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION

Figure 11. Voltage Regulator Control Knob

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three

Figure 9. G.F.C.I. Receptacle

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 position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

voltage regulator control knob

increase

decrease

Output Terminal Lugs

(Figure 11) on the

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can when the voltage selector switch is placed in the

phase 240/120 position.

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 23

only

be accessed

single-

DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 110A switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convenience receptacles (Figure 13).

main

circuit breaker is provided. Make sure to

Output

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the

Selector Switch

Voltage

(Figure 15).

Figure 15. Blower Fan Fuse

Figure 13. Connecting Loads

Figure 14. Over Current Relay

Over Current Relay

over current relay

circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the rent relay must be pressed. The over current relay is located in the control box.

(Figure 14) is connected to the main

reset button

on the over cur-

DANGER - ELECTROCUTION HAZARDS

This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating could result in

bodily harm

completely off before attempting to replace or handle this fuse.

electrocution

. ALWAYS turn the unit

and

severe

PAGE 24 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

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