Multiquip DCA-56SPX User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATT
TM
SERIES
MODEL DCA-56SPX
60 Hz GENERATOR
(PARTS LIST NO. B4871301604 S/N 3796699~)
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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
NOTE PAGE
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 3
MQ POWER DCA-56SPXMQ POWER DCA-56SPX
MQ POWER DCA-56SPX
MQ POWER DCA-56SPXMQ POWER DCA-56SPX
TMTM
TM
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
WW
W
WW
AA
A
AA
TTTT
TT
TTTT
TMTM
GENERATORGENERATOR
GENERATOR
GENERATORGENERATOR
TABLE OF CONTENTS
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly .................................................. 56-57
Control Box Assembly ............................................... 58-59
Engine and Radiator Assembly ................................. 60-65
Output Terminal Assembly ......................................... 66-67
Actuaror Assembly .................................................... 68-69
Battery Assembly ...................................................... 70-71
Muffler Assembly ...................................................... 72-73
Fuel Tank Assembly .................................................. 74-75
Enclosure Assembly ................................................. 76-79
Rubber Seals Assembly ............................................ 80-81
Nameplate and Decals .............................................. 82-83
Terms and Condition of Sale — Parts ............................ 84
Specification and part
NOTE
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
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-56SPX— 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!
1
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DCA-56SPX — SPECIFICATIONS
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PAGE 6 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
Figure 1. Dimensions
DCA-56SPX — DIMENSIONS (TOP, SIDE AND FRONT)
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1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 7
DCA-56SPX — 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-56SPX
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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
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-56SPX — 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)
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 9
DCA-56SPX — 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-56SPX 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — 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
r.
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
■
■
■
or
■
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.
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 11
DCA-56SPX — 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
or
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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — RULES FOR SAFE OPERATION
ACCIRCUIT
BREAKER
OFF
2
2
A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
O
F
F
22
A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
O
FF
22
A
120
V
20A
120V
OFF
ON
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
or
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
F
F
2A
O
2
ACCIRCUIT
2900
GA-2.9R
F
A
F
2
O
2
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
F
A
F
2
O
2
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
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 13
DCA-56SPX — 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
NOTE
For more saftey tips, see the trailer saftey
guidelines section in this manual.
NOTE PAGE
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 15
DCA-56SPX — GENERATOR DECALS
The DCA-56SPX 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
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DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 17
DCA-56SPX — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 18 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — 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.
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DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 19
DCA-56SPX — GENERAL INFORMATION
DCA-56SPX Whisperwatt™ Series Familiarization
Generator
The MQ Power Model DCA-56SPX is a 56 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-56SPX 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
■■
■■
■
Pre-Heat Button
■■
■■
■
Pre-Heat Lamp
■■
■■
■
Auto ON/OFF Engine Controller (MPEC)
■■
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, 250 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-56SPX is powered by a 4 cylinder, water cooled,
direct injection turbocharged,
engine
. This 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
" and responds
Isuzu Model FF-4BGIT diesel
PAGE 20 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — MAJOR COMPONENTS
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.ONMETINOITPIRCSED
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ssAyrettaB
Figure 5. Major Components
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DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 21
nignE
1
NOTE PAGE
PAGE 22 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of
the DCA-56SPX
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
■■
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
NOTE
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
6. Main Circuit Breaker – This three-pole, 250A main
breaker is provided to protect the the
Terminal Lugs
from overload.
U,O, and V Output
automatically trip the 250 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,O and V
to the
load.
Output Terminal Panel
, press the
main
closed
position (ON).
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DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 23
DCA-56SPX — ENGINE OPERATING PANEL
1
3
2
4
5
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE
10
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
6
7
8
9
Figure 7. Engine Operating Panel
PAGE 24 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
DCA-56SPX — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-56SPX
1. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. (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. Pre-Heat Lamp – When ECU is placed in AUTO position
pre-heat lamp will be ON. When pre-heating cycle is
completed, lamp will trun OFF.
9. Pre-Heat Button – Press this button when starting the
engine in cold weather conditions. Once the engine glow
plugs have warmed, the engine will start automatically.
10. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical row of status LED's (inset),
that when lit, indicate that an engine malfunction (fault)
has been detected. When a fault
has been detected the engine
controller will evaluate the fault
and all major faults will shutdown
the generator. 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
F. Engine Running – Indicates that engine is running at
a safe operating speed.
Over
mode. If the engine engages at a speed
Over Speed Protection
major
fault.
mode.
fault.
major
major
fault.
1
DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 25
DCA-56SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The
Output Terminal Panel
(Figure 8) shown below is located
on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
Output Terminal Familiarization
The “
Output Terminal Panel
following:
■■
■
Three 120/240V output receptacles (CS-6369), 50A
■■
lugs.
■■
■
Three 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)
■■
” (Figure 8) is provided with the
Figure 8. Output Terminal Panel
PAGE 26 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)
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