Multiquip DCA-600SSV User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATT
TM
SERIES
MODEL DCA-600SSV
60 Hz GENERATOR
PARTS LIST NO. C4874303204
Revision #0 (07/13/07)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
Multiquip at 1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153), go to http://www.nhtsa.dot.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 3
TABLE OF CONTENTS
MQ Power DCA-600SSVMQ Power DCA-600SSV
MQ Power DCA-600SSV
MQ Power DCA-600SSVMQ Power DCA-600SSV
60 Hz AC Generator60 Hz AC Generator
60 Hz AC Generator
60 Hz AC Generator60 Hz AC Generator
California Proposition 65 Warning ..................................... 2
Reporting Safet Defects ................................................... 3
Table of Contents.............................................................. 4
Parts Ordering Procedures ...............................................5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) .......................................... 7
Safety Alert Messages Symbols ................................... 8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals....................................................... 14-17
Installation ................................................................. 18-19
General Information ........................................................ 20
Major Components ......................................................... 21
Generator Control Panel ............................................ 22-23
Engine Operating Panel ............................................. 24-25
Output Terminal Panel Familiarization ........................ 26-28
Load Application ............................................................. 29
Generator Outputs .......................................................... 30
Generator Outputs/Gauge Reading ................................. 31
Output Terminal Panel Connections ........................... 32-33
Pre Setup .................................................................. 34-38
Generator Start-up Procedure ( Manual MPEC) ........ 39-41
Generator Start-up Procedure (Auto MPEC) .................. 42
Generator Shutdown Procedure ...................................... 43
Maintenance (Engine) ................................................ 44-47
Maintenance (Trailer) ................................................. 48-50
Trailer Wiring Diagram ................................................ 51-52
Generator Wiring Diagram ............................................... 53
Generator Wiring Diagram (Main Breaker) ...................... 54
Engine Wiring Diagram .............................................. 55-56
Engine Troubleshooting .............................................. 57-58
Generator Troubleshooting .............................................. 59
Engine Contoller Troubleshooting (MPEC) ...................... 60
Troubleshooting Diagnostic Lamp ................................... 61
Explanation of Codes in Remarks Column ..................... 62
Suggested Spare Parts .................................................. 63
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly .......................................... 64-67
Control Box Assembly ........................................ 68-73
Engine Radiator Assembly ................................. 74-77
Engine Operating Panel Assembly .................... 78-79
Output Terminal Assembly ................................. 80-83
Battery Assembly ............................................... 84-85
Muffler Assembly ............................................... 86-87
Fuel Tank Assembly ........................................... 88-89
Enclosure #1 Assembly...................................... 90-93
Enclosure #2 Assembly...................................... 94-97
Enclosure #3 Assembly...................................... 98-99
Enclosure (Rubber Seals) .............................. 100-101
Nameplate and Decals................................... 102-105
Terms and Conditions Of Sale — Parts ................ 106
NOTE
Specification and part
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
Goto www.multiquip.com and click on
Order Par ts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
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
Use the
internet
Standard orders
on
Fax
your order in and qualify for a 2% Discount
on
Standard orders
Domestic (US) Dealers Call:
and qualify for a 5% Discount
for all orders which include
for all orders which include
International Customers
their local Multiquip Representatives for
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
should contact
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
www.mqpower.com
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 5
When ordering parts, please supply:
❒❒
❒
Dealer Account Number
Dealer Name and Address
Shipping Address (if different than billing address)
Return Fax Number
Applicable Model Number
All orders are treated as
and will ship the same day if received prior
WE ACCEPT ALL MAJOR CREDIT CARDS!
❒❒
Standard Orders
Specify Preferred Method of Shipment:
✓
UPS/Fed Ex
■
Priority One
■
Ground
■ Next Day
✓ DHL
✓
Tru ck
DCA-600SSV — SPECIFICATIONS
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PAGE 6 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — DIMENSIONS (TOP, SIDE AND FRONT)
TOP VIEW
B
A
Figure 1. Dimensions
SIDE VIEW
C
D
G
H
E
F
600
REAR VIEW
(CONTROL PANEL VIEW)
J
K
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 7
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DCA-600SSV — 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
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.
developed to provide complete
instructions for the safe and
efficient operation of the
MQPower
WHISPERWATT™ GENERATOR.
Model
DCA-600SSV
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
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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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-600SSV — 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
NOTE
This generator, other property,
or the surrounding environment
could be damaged if you do not
follow instructions.
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 9
DCA-600SSV — 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
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.
or even
DEATH
! This equipment is to be
DCA-600SSV Whisperwatt™ Generator.
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
■
■
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.
VOLVO Engine Owner's Manual
manual mode
for engine
PAGE 10 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — 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
or
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
U
N
V
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 5.
■
NEVER power cables or cords
■
NEVER
stand in water
while AC power from the generator
lay in wate
r.
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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 11
DCA-600SSV— 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.
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 handleing 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.
Turn all circuit breakers OFF
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
clothing or skin
EYES
wear safety
severe injury
, rinse eyes immediately with
or
DEATH:
, rinse skin or clothing
■
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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — 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:
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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — 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-600SSV — GENERATOR DECALS
Machine Safety Decals
The DCA-600SSV generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustrations below and on the preceding pages shows 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 14 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — GENERATOR DECALS
Figure 2. Generator Decals
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 15
DCA-600SSV — GENERATOR DECALS
Figure 2. Generator Decals
PAGE 16 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — GENERATOR DECALS
Figure 3. Generator Decals
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 17
DCA-600SSV — INSTALLATION
DCA-600SSV — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 18 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — INSTALLATION
Outdoor Installation
Install the generator in a area that is free of
bystanders
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.
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.
, and
overhead obstructions
CAUTION - EXHAUST HAZARD
. Make sure the
debris
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.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set 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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 19
DCA-600SSV — GENERAL INFORMATION
DCA-600SSVWhisperwatt™ Series Familiarization
Generator
The MQ Power Model DCA-600SSV is a 528 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:
■■
Tachometer/Hour Meter Gauge
■
■■
■■
Water Temperature Gauge / Water Temp. Alarm Lamp
■
■■
■■
Oil Pressure Gauge / Oil Pressure Alarm Lamp
■
■■
■■
Charging Alarm Lamp
■
■■
■■
■
Fuel Level Gauge / Low Fuel Warning Alarm Lamp
■■
■■
■
Pre-Heat Button / Pre-Heat Lamp
■■
■■
■
Air Filter Alarm Lamp
■■
■■
■
Engine Speed Switch
■■
■■
■
Battery Switch
■■
■■
■
Emergency Stop 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
■■
■■
■
Voltmeter Change-Over Switch
■■
■■
■
Voltage Regulator
■■
■■
■
Panel Light/Panel Light Switch
■■
■■
■
3-Pole, 1,600 amp Main Circuit Breaker
■■
■■
■
Engine Control Unit (Computer Controlled)
■■
■■
■
“Control Box” (Located Behind Gen. Control Panel)
■■
■■
■
Automatic Voltage Regulator
■■
■■
■
Current Transformer
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer
■■
■■
■
Starter Relay
■■
■■
■
Voltage Change-over Board
■■
Open Delta Excitation System
The DCA-600SSV generator is equipped with the state of
the art "
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.
Engine
The DCA-600SSV is powered by a 4 cycle, water cooled,
turbocharged
Engine
requirement for the generator. Reference Table 2 for engine
specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Electronic 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%.
Output Terminal Panel
Extension Cables
The “Output Terminal Panel” is provided with the following:
■■
■
Three 120/240V output receptacles (CS-6369), 50A
■■
■■
■
Three auxilliary circuit breakers, 50A
■■
■■
■
Two 120V output receptacles (GFCI), 20A
■■
■■
■
Two GFCI circuit breakers, 20A
■■
■■
■
Four output terminal boards (3Ø power)
■■
■■
■
Ground terminal
■■
■■
■
Battery Charger (Optional)
■■
■■
■
Water Heater (Optional)
■■
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.
Open-Delta
" excitation system. The open delta
fixed ceiling
" and responds
VOLVO Model PENTA TAD1642GE Diesel
. This engine is designed to meet every performance
PAGE 20 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — MAJOR COMPONENTS
DCA-600SSV — MAJOR COMPONENTS
Tabl e 4. Generator Major Components
ITEM NO. DESCRIPTION
1 Enclosure Assembly
2 Air Cleaner Assembly
3 Muffler Assembly
4 Fuel Tank Assembly
5 Engine and Radiator Assembly
6 Battery Assembly
7 Generator Assembly
8 Output Terminal Assembly
9 Generator Control Panel Assembly
10 Engine Operating Panel Assembly
Figure 5. Major Components
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 21
DCA-600SSV — GENERATOR CONTROL PANEL
1
3
HZ
6
2
11
10
4
A
5
V
14
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
7
8
9
13
12
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of
the DCA-600SSV "
Control Panel
" (Figure 6).
1. Pilot Lamp – Indicates that the generator is working
properly.
2. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
lit this light will make it easier to read the meters and
gauges. When the generator is not in use be sure to
turn the panel light switch to the OFF position.
3. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
4. AC Ammeter – Indicates the amount of current the
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.
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
8. Panel Light Switch – When activated, this switch will
turn on the luminate the control panel.
9. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage
load is drawing from the generator.
5. AC Voltmeter – Indicates the single phase output
voltage present at the UVWO terminals. .
PAGE 22 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — GENERATOR CONTROL PANEL
10. Circuit Breaker OFF Lamp – When the circuit
breaker ON switch is placed in the OFF position this
lamp will be turned OFF.
11. Circuit Breaker ON Lamp – When the circuit breaker
ON switch is placed in the ON position this lamp will
be turned ON.
12. Circuit Breaker OFF Switch – Press this switch to
place the 1600 amp circuit breaker in the open (OFF)
position.
13. Circuit Breaker ON Switch – Press this switch to
place the 1600 amp circuit breaker in the closed (ON)
position.
14. Auto On/Off Engine Controller (MPEC) – This
controller has a vertical row of status LED's (inset),
that when lit, indicates 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
MPEC will attempt to crank
the engine for 10 seconds
before disengaging.
During
the engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the controller will shutdown the engine by
initializing the "
cranking cycle
cranking cycle
Over Speed Protection
, The
, The MPEC will attempt to crank
" mode.
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 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a
shut down the generator.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 215°F. 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 be started a pre- programmed number of
times, and has failed to start. The number of cycles
and duration are programmable. Typical programmable
start settings is 3 cycles with a 10 second duration.
This is considered a
the generator.
E. Overspeed Shutdown – Indicates that the engine is
running at an unsafe speed. This is considered a
fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
major
fault and will
fault and will shut down the generator.
major
fault and will shut down
major
Also the MPEC will shutdown the generator 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 MPEC module.
A. Off/Manual/Auto Switch – This switch controls the
running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the
immediately.
manual
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 23
position, the generator will start
DCA-600SSV — ENGINE OPERATING PANEL
1
TACHOMETER
11
5
6
7
WATERTEMP.
OILPRESS. FUEL LEVEL
2
CHARGE
AIRFILTER
BATTERY SWITCH
ON
OFF
8
3
PRE-HEAT
LAMP
PRE-HEAT
BUTTON
9
4
EMERGENCY
STOP
ENGINE SPEED
HIGH
LOW
10
Figure 7. Engine Operating Panels
PAGE 24 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of the
DCA-600SSV "
Engine Operating Panels
" (Figure 7).
1. 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.
2. Engine Warning Display (LED) Module – This module
display’s the following engine failures:
A. Overheat Lamp – This lamp goes ON when
the cooling water temperature rises abnormally.
If the lamp goes ON during normal operation of
the generator, the emergency shutdown device
will stop the engine automatically.
WATER TEMP.
3. Pre-Heat Lamp – Indicates that the glow plugs of the
diesel engine are hot and the engine is ready to be started.
4. Emergency Stop Button – Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a normal means of stopping the engine.
5. Oil Pressure Gauge – During normal operation this gauge
be should read in the “GREEN” zone. When starting the
generator the oil pressure mar read a little bit higher, but
after the engine warms up the oil pressure should return to
the green zone.
6. Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
7. Fuel Level Gauge – Indicates amount of diesel fuel
remaining.
8. Battery Switch – This switch should be set to the ON
B. Low Oil Pressure Lamp – During normal operation of the
generator this lamp should remain OFF. When the AutoOFF/Reset-Manual switch is set to the
“Manual” position to start the engine, the lamp
will illuminate. After the oil pressure rises after
start-up the lamp will go OFF. If this lamp is
position during normal operation. When the engine has
been stop, place this switch in the OFF position. DO NOT
turn this switch during normal operation, it could cause
damage to the electrical equipment.
9. Preheat Switch – Press on to heat glow plugs in cold
weather conditions.
ever illuminated (ON) during normal operation
of the generator, the emergency shutdown
device will stop the engine automatically.
C. Low Fuel Level Lamp – When this lamp is
ON, it is time to stop the engine and add fuel.
OIL PRESS.
10. Engine Speed Switch – This switch changes the engine
speed from idle to normal.
Hour Meter Switch - Press this pushbutton switch to
11.
activate hour meter. Indicates the number hours
equipment has been in operational use.
Remember to let the engine cool before
adding fuel.
FUEL LEVEL
D. Charge Lamp – This lamp goes ON when
the electrical charging system is not working
properly.
E. Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this lamp
goes ON during normal operation of the
generator, stop the engine and replace the air
filter.
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 25
BATTERY
AIR FILTER
DCA-600SSV — OUTPUT TERMINAL FAMILIARIZATION
Output Terminal Familiarization
The “
Output Terminal Panel
the following:
Three 240/139V output receptacles, 50 amp
Three AUX. circuit breakers 240V @50 amps
Two 120V GFCI receptacles, 20 amp
Two (2) GFCI circuit breakers 120V@ 20 amps
Eight (16) output terminal lugs
Figure 8. Output Terminal Panel
” (Figure 8) is provided with
Output Terminal Panel
Shown below (Figure 8) is the
up on the cover to gain access to receptacles and terminal
lugs.
NOTE
Output Terminal Panel
Terminal legs "O" and "Ground"
are considered
bonded grounds
, lift
.
PAGE 26 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
board
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 UVWO terminals.
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
Test Button
voltage change-over
" (See Figure 9) in
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
UVWO terminals.
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Figure 11. Voltage Regulator Control Knob
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
(Figure 11) on the
Figure 9 G.F.C.I. Receptacle
Twist Lock Dual Voltage 240/139 VAC Receptacles
There are three 240/139 VAC, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output
terminal panel. These receptacles can be accessed in any
voltage change-over board
Figure 10. 240/139 VAC Twist-Lock
Auxiliary Receptacles
position.
DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 27
DCA-600SSV — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the UVWO terminal
lugs or the convenience receptacles. (See Figure 12). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3pole, 1,600 amp,
sure to switch
prior to starting the engine.
main
circuit breaker is provided. Make
ALL
circuit breakers to the "OFF" position
Over Current Relay
An
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 13) is connected to the main
reset button
Figure 13. Over Current Relay
on the over cur-
Figure 12. Connecting Loads
Maximum Power Output (KW)
The entire load connected to the UVWO output terminal lugs,
duplex and auxiliary receptacles must not exceed 528 kW in
standby or 480 kW in prime output.
PAGE 28 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
DCA-600SSV— LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
NOTE
starting system of the equipment.
If wattage is not given on the equipment's
NOTE
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 5.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
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0.1
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
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DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 29
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any building’s electrical
system, a
(transfer) switch
licensed electrician
must install an
. Serious damage to the building’s
isolation
electrical system may occur without this transfer switch.
If 3Ø load (kVA) is not given on
the equipment nameplate,
NOTE
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
DCA-600SSV — GENERATOR OUTPUTS
Generator Output Voltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by applying jumpers (6) to the
voltage change-over board
(Figure 15).
Maximum Amps
Table 8 shows the
vide. DO NOT exceed the maximum amps as listed.
To obtain some of the voltages as listed in Table 7 (see
below) will require a fine adjustment using the
lator
(VR)
control knob
located on the control panel.
voltage regu-
Voltage Change-Over Board
The
voltage change-over board
(Figure 14) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
maximum
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Figure 14. Voltage Change-Over Board
240V Configuration
DANGER - CHANGING JUMPER PLATES
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation. There
exists the possibility of electrocution, electrical shock or
burn, which can cause severe bodily harm or even death!
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PAGE 30 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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