Multiquip DCA70SSIU2 User Manual

OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA70SSIU2
(ISUZU BJ-4JJ1X DIESEL ENGINE)
PARTS LIST NO. M2870300604
Revision #0 (05/29/09)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
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 Traffi c 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 fi nds 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: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from http://www.safecar.gov.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 3
TABLE OF CONTENTS
DCA70SSIU2 Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ............................................................. 14
Installation ............................................................. 15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ................................................. 26
How To Read AC Ammeter/AC Voltmeter Gauges 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Generator Start-Up Procedure ........................ 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance ..................................................... 37-39
Trailer Maintenance .......................................... 40-43
Trailer Wiring Diagram ........................................... 44
Generator Wiring Diagram ..................................... 45
Engine Wiring Diagram .......................................... 46
Troubleshooting (Generator) .................................. 47
Troubleshooting (Diagnostic Lamp) ....................... 48
Component Drawings
Generator Assy. ................................................ 52-53
Control Box Assy. .............................................. 54-59
Engine And Radiator Assy. ............................... 60-63
Output Terminal Assy. ....................................... 64-65
Battery Assy. ..................................................... 66-67
Muffl er Assy. ..................................................... 68-69
Fuel Tank Assy. ................................................ 70-71
Enclosure Assy. ................................................ 72-77
Rubber Seals Assy. ...........................................78-79
Nameplate And Decals Assy. ........................... 80-81
Terms And Conditions Of Sale — Parts ................ 82
Explanation Of Code In Remarks Column............. 50
Suggested Spare Parts ......................................... 51
PAGE 4 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
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 Parts
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.
When ordering parts, please supply:
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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
R Specify Preferred Method of Shipment: UPS/Fed Ex DHL
N Priority One Tr uck  N Ground N Next Day N Second/Third Day
www.mqpower.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifi cally address the level of exposure to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.
NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.
NEVER operate this equipment under the infl uence of drugs or alcohol.
ALWAYS check the equipment for loosened threads or bolts before starting.
DO NOT use the equipment for any purpose other than its intended purposes or applications.
NEVER use accessories or attachments that are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest fi re extinguisher.
ALWAYS know the location of the nearest fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and fi re department. This information will be invaluable in the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation will void all warranties.
NEVER disconnect any emergency or safety devices. 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.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts immediately.
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 unauthorized personnel
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.
The engine of this equipment requires an adequate free fl ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free fl ow of the air is restricted. If the air fl ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or guards removed.
Keep fi ngers, hands hair and clothing away from all moving parts to prevent injury.
DO NOT remove the radiator cap while the engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.
DO NOT remove the coolant drain plug while the engine is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.
DO NOT remove the engine oil drain plug while the engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter frequently to prevent engine malfunction.
NEVER tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.
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 suffi cient 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 turbochargers, and reduce the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel.
Wet stacking does not 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.
State Health Safety Codes and Public Resources Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.
PAGE 8 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from sparks and open fl ames.
ALWAYS use extreme caution when working with fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system.
Store fuel in appropriate containers, in well-ventilated areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety towing regulations, in addition to meeting
Department of Transportation (DOT) Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety information.
In order to reduce the possibility of an accident while transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.
ALWAYS shutdown engine before transporting
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.
Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be infl ated to 50 psi cold. Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional, backup, brake and trailer lights are connected and working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie wraps.
The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.
Avoid sudden stops and starts. This can cause skidding, or jack-knifi ng. Smooth, gradual starts and stops will improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times when towing.
Raise and lock trailer wheel stand in up position when towing.
Place chock blocks underneath wheel to prevent rolling while parked.
Place support blocks underneath the trailer’s bumper to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.
NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.
Backfeed to a utility system can cause
electrocution and/or property damage. NEVER connect the generator to a
building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.
NOTICE
ALWAYS make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death by electrocution can result from operating an ungrounded generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation.
NEVER grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground, down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition. Repair or replace all worn cables.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 11
SPECIFICATIONS
Generator Specifi cationsTable 1.
Model
Type
Armature Connection Star with Neutral Zigzag
Phase
Standby Output
Prime Output
77 kVA (62 kW) 44 KW
70 kVA (56 KW) 40 KW
Revolving fi eld, self ventilated,
open protected type synchronous generator
3 Single
DCA-70SSIU2
Voltage
Frequency
Speed
Power Factor
Aux. AC Power
Voltage
Output
Weight (No Fuel)
Weight (Fuel)
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
240 or 480V 240 or 120V
60 Hz
1800 rpm
0.8 1.0
Single Phase, 60 Hz
120V
4.8 Kw (2.4 kW x 2)
2,701 lbs. (1,225 kg.)
3,035 lbs. (1,376 kg.)
Engine Specifi cationsTable 2.
ISUZU BJ4JJ1X Tier 3
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
3.76 in. x 4.13 in. (95.4 mm x 105 mm)
183 cu. in. (3,000 cc)
85 HP/1800 RPM
Electric
3.09 gal. (11.7 liters)
3.96 gal. (15.0 liters)
#2 Diesel Fuel
40 gal. (150 liters)
4.1 gal. (15.4 L)/hr at full load 3.1 gal. (11.9 L)/hr at 3/4 load
2.2 gal. (8.40 L)/hr at 1/2 load 1.4 gal. (5.20 L)/hr at 1/4 load
12V 72Ah x 1
PAGE 12 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
DIMENSIONS
DimensionsFigure 1.
DimensionsTable 3.
Reference
Letter
A 30.31 in. (770 mm.) F 94.49 in. (2,400 mm.)
B 30.50 in. (775 mm.) G 55.12 in. (1,400 mm.)
C 35.80 in. (910 mm.) H 35.43 in. (900 mm.)
D 30.50 in. (775 mm.)
E 35.80 in. (910 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 13
INSTALLATION
Typical Generator Grounding ApplicationFigure 2.
PAGE 14 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
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
Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.
GENERATOR GROUNDING
To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.
Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifi es 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:
Use one of the following wire types to connect the 1. generator to earth ground.
Copper - 10 AWG (5.3 mm2) or larger.a.
Aluminum - 8 AWG (8.4 mm2) or larger.b.
When grounding the generator (Figure 2) connect the 2. ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.
INDOOR INSTALLATION
Exhaust gases from diesel engines are 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 fi rmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the fl oor 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.
NEC article 250-52(c) specifi es that the earth ground rod 3. should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 15
GENERAL INFORMATION
GENERATOR
The MQ Power Model DCA70SSIU2 generator (Figure 3) is 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 Warning Lamp Pre-Heat Lamp Oil Pressure Gauge Charging Ammeter Gauge Fuel Level Gauge Panel Light/Panel Light Switch ECU Controller Engine Speed Switch
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, 175 amp Main Circuit Breaker “Control Box” (located behind the Gen. Control Panel)
Automatic Voltage Regulator• Current Transformer• Over-Current Relay• 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)
OPEN DELTA EXCITATION SYSTEM
This generator is equipped with the state of the art “Open­Delta” excitation system. The open delta system consist
of an electrically independent winding wound among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectifi ed 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 confi guration 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 “fi xed ceiling” and responds according the demands of the required load.
ENGINE
This generator unit incorporates an ISUZU BJ-4JJ1X diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine
specifi cations.
In keeping with MQ Power’s policy of constantly improving its products, the specifi cations 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.
PAGE 16 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
MAJOR COMPONENTS
Generator Major ComponentsTable 4.
ITEM NO. DESCRIPTION
1 Muffl er Assembly
2 Engine Assembly
3 Enclosure Assembly
4 Generator Assembly
5 Output Terminal Assembly
6 Battery Assembly
7 Fuel Tank Assembly
8 Generator Control Panel Assembly
9 Engine Operating Panel Assembly
Major ComponentsFigure 3.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 17
GENERATOR CONTROL PANEL
1
AUTO
MANUAL
OFF/RESET
LOW OILPRESSURE HIGH COOLANTTEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING
MOOOOO-20001Q
1000
2000
0
3000
RPM
Generator Control PanelFigure 4.
The defi nitions below describe the controls and functions of the Generator Control Panel (Figure 4).
Voltage Regulator Control 1. — Allows ±15% manual
adjustment of the generator’s output voltage.
Main Circuit Breaker2. —This three-pole, 175A main
breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.
7
6
INCREASE
DECREASE
2
V
U
W
3
OFF
V-W
W-U
U-V
OFF
5
4
Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.
The Control Box is equipped with the following major components:
Over-Current Relay
Ammeter Change-Over Switch 3. — This switch allows
the AC ammeter to indicate the current fl owing 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.
Voltmeter Change-Over Switch 4. — 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.
AC Voltmeter 5. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
AC Ammeter 6. — Indicates the amount of current the
load is drawing from the generator per leg selected by the ammeter phase-selector switch.
Frequency Meter 7. — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current fl owing from the U,V, and W Output Terminal Lugs to the load.
In the event of a short circuit or over current condition, it will automatically trip the 175 amp main breaker.
To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 18 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
NOTES
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 19
ENGINE OPERATING PANEL
1
8
9
11
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING
MOOOOO-20001Q
10
3
2
INCREASE
DECREASE
4
V
U
W
5
6
1000
2000
7
0
3000
RPM
Engine Operating PanelFigure 5.
OFF
V-W
W-U
U-V
OFF
PAGE 20 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
ENGINE OPERATING PANEL
The defi nitions below describe the controls and functions of the Engine Operating Panel (Figure 5).
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
Panel Light 1. — 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.
Panel Light Switch
2. — When activated will turn on control
panel light.
Oil Pressure Gauge
3. — During normal operation this
gauge should read between 42 ~71 psi. (290~490 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.
Water Temperature Gauge
4. — During normal operation this
gauge be should read between 167°~203°F (75° ~95°C
Charging Ammeter Gauge
5. — Indicates the current
being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.
Fuel Gauge
6. — Indicates amount of diesel fuel available.
7. — Indicates engine speed in RPM’s for 60
Tachometer
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.
Preheat Lamp
8. — As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine glow plugs. When the lamp turns off, this indicates that the preheat cycle is complte and the engine will start automatically.
Warning Lamp
9. — This lamp will illuminate when a critical
engine fault has occured.
Engine Speed Switch
10. — This switch controls the speed
of the engine (low/high).
Auto START/STOP Engine Controller (ECU) 11. — This
engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the Over Speed Protection mode.
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.
MPEC Control Switch A. — 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.
Low Oil Pressure B. — Indicates the engine pressure has fallen below 15 psi (103 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.
High Coolant Temperature C. — Indicates the engine temperature has exceeded 230°F (110°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.
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 cranking cycle, the ECU will attempt to crank the engine for 10 seconds before disengaging.
Overcrank Shutdown D. — 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 major fault.
Overspeed Shutdown E. — Indicates the engine is running at an unsafe speed. This is considered a major fault.
Engine Running F. — Indicates that engine is running at a safe operating speed.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.
NOTICE
Terminal legs “O” and “Ground” are considered bonded grounds.
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with the following:
Three 120/240V output receptacles @ 50 amp
Three Circuit Breakers @ 50 amps
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Output Terminal PanelFigure 6.
PAGE 22 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch 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 reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.
Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the Output Terminal Lugs.
Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.
Voltage Regulator Control KnobFigure 9.
Removing the Plastic Face Plate (Hard Wire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face plate cover (Figure 10). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.
G.F.C.I. ReceptacleFigure 7.
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the single-
phase 240/120 position.
120/240V Twist-Lock Auxiliary Figure 8.
Receptacles
After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.
Plastic Face Plate (Output Terminal Figure 10.
Lugs)
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 23
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11).
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, 175A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.
Over Current Relay
An over current relay (Figure 12) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.
Over Current RelayFigure 12.
Connecting LoadsFigure 11.
PAGE 24 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.
Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is infl uenced by the effi ciency, power factor and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below when connecting loads.
Power Factor By LoadTable 5.
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
THREE PHASE LOAD
When calculating the power requirements for 3-phase power use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motor-driven equipment draw much greater current for starting than during operation.
An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.
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.
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
Electronic devices, communication equipment
1.0
Common power tools 0.8
Cable Selection (60 Hz, Single Phase Operation)Table 6.
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
When connecting a fl uorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.
When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.
When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.
DANGER
Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.
DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 25
GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 13). To obtain some of the voltages as listed in Table 7 (see below) will require a fi ne adjustment using the voltage regulator (VR) control
knob located on the control panel.
Voltage Selector Switch
The voltage selector switch (Figure 13) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.
Generator Amperage
Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed..
Generator Maximum AmpsTable 8.
Rated Voltage Maximum Amps
1Ø 120 Volt 155.5 X 2 amps (4 wire)
1Ø 240 Volt 78.8 amps (4 wire)
3Ø 240 Volt 168 amps
3Ø 480 Volt 84 amps
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.
Tables 9 and 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.
Voltage Change-Over BoardFigure 13.
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch, press and hold the red button located at the bottom of the switch.
CAUTION
NEVER change the position of the voltage selector switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting voltage.
Voltages AvailableTable 7.
Three Phase
(Switchable)
Single Phase
(Switchable)
208V 220V 240V 416V 440V 480V
120V 1127V 139V 240V 254V 277V
1Ø GFCI Receptacle Load CapacityTable 9.
KW in Use
Twist Lock (C6369)
1Ø 240/120V
40.4 0
39.2 5 amps/receptacle
38.0 10 amps/receptacle
38.6 15 amps/receptacle
35.6 20 amps/receptacle
3Ø Generator Maximum AmpsTable 10.
KVA in Use
(UVWO Terminals)
3Ø 240/480V
70
65.8
61.7
57.5
53.4
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
0 amps/receptacle
5 amps/receptacle
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
PAGE 26 — DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09)
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