whisperwatt series model dca-220ssvu · 2016. 12. 28. · page 8 — dca-220ssvu— operation and...

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUAL

Revision #1 (01/20/06)

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.

WHISPERWATTTM SERIESMODEL DCA-220SSVU

60 Hz GENERATORPARTS LIST NO. M4870300024A

— DCA-220SSVU— OPERATION AND PARTS MANUAL — REV. #1 (01/20/06)

DCA-220SSVU— OPERATION AND PARTS MANUAL — REV. #1 (01/20/06) — PAGE 3

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© COPYRIGHT 2005, MULTIQUIP INC.

MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used,reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used withpermission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment andshould remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations arebased on the DCA-220SSVU WHISPERWATT AC Generator. Multiquip Inc. reserves the right to discontinue or change specifications,design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of thispublication, visit our website at:

www.mqpower.com

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLINGMQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-835-2551 FAX: 310-638-8046WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279


TABLE OF CONTENTS

Specification and partnumber are subject tochange without notice.

NOTE

MQ POWER DCA-220SSVUMQ POWER DCA-220SSVUMQ POWER DCA-220SSVUMQ POWER DCA-220SSVUMQ POWER DCA-220SSVUWHISPERWHISPERWHISPERWHISPERWHISPERWWWWWAAAAATTTTTTTTTTTMTMTMTMTM GENERATORGENERATORGENERATORGENERATORGENERATORCalifornia Proposition 65 Warning ..................................... 2Here's How To Get Help .................................................... 3Table Of Contents ............................................................. 4Parts Ordering Procedures ............................................... 5Specifications ................................................................... 6Dimensions (Top, Side, Front) ........................................... 7Safety Message Alert Symbols .................................... 8-9Rules for Safe Operation ........................................... 10-13Generator Decals ....................................................... 14-15Installation ................................................................. 16-17General Information ........................................................ 18Major Components ......................................................... 19Generator Control Panel ................................................. 21Engine Operating Panel ............................................. 22-23Output Terminal Panel Familiarization ........................ 24-26Load Application ............................................................. 27Generator Outputs .......................................................... 28Gauge Reading ............................................................... 29Output Terminal Panel Connections ........................... 30-31Pre-Setup .................................................................. 32-35Generator Start-up Procedure (Manual) ..................... 36-37Generator Start-up Procedure (Auto Mode) .................... 38Generator Shut-Down Procedure .................................... 39Maintenance (Engine) ................................................ 40-41Jacket Water Heater/battery Charger (Option) ................ 42Maintenance (Trailer) ................................................. 43-46Trailer Wiring Diagram ..................................................... 47Generator Wiring Diagram ............................................... 48Engine Wiring Diagram ................................................... 49Generator Troubleshooting .............................................. 50Engine Controller Troubleshooting ................................... 51Explanation of Code in Remarks Column ....................... 52Suggested Spare Parts .................................................. 53

Generator Assembly .................................................. 54-57Control Panel Assembly ............................................ 58-59Control Box Assembly ............................................... 60-63Engine and Radiator Assembly ................................. 64-67Output Terminal Assembly ......................................... 68-69Battery Assembly ...................................................... 70-71Muffler Assembly ...................................................... 72-73Fuel Tank Assembly .................................................. 74-75Enclosure Assembly ................................................. 76-79Rubber Seals Assembly ............................................ 80-81Nameplate and Decals .............................................. 82-83

Terms and Condition of Sale — Parts ............................ 84

COMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRAWINGSWINGSWINGSWINGSWINGS


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MQPOWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-537-3700 • 800-421-1244FAX: 310-632-2656E-MAIL: [email protected]: www.mqpower.com

When ordering parts,please supply the following information:

❒❒❒❒❒ Dealer account number❒❒❒❒❒ Dealer name and address❒❒❒❒❒ Shipping address (if different than billing address)❒❒❒❒❒ Return fax number❒❒❒❒❒ Applicable model number❒❒❒❒❒ Quantity, part number and description of each part❒❒❒❒❒ Specify preferred method of shipment:

✓ FedEx or UPS Ground✓ FedEx or UPS Second Day or Third Day✓ FedEx or UPS Next Day✓ Federal Express Priority One✓ DHL✓ Truck

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

Extra Discounts!All parts orders which include complete part numbers andare received by our automated web parts order system, orby fax qualify for the following extra discounts:

Ordered Standard Stock ordersvia orders ($750 list and above)Fax 3% 10%

Web 5% 10%

Special freight allowanceswhen you order 10 or moreline items via Web or Fax!**FedEx Ground Service at no charge for freightNo other allowances on freight shipped by any other carrier.**Common nuts, bolts and washers (all items under $1.00list price) do not count towards the 10+ line items.

Place Your Parts Order Via Web or FaxFor Even More Savings!

(Domestic USA Dealers Only)

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

Here’s how to get help...Please have the model and serial numberon hand when calling.

MQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-835-2551 FAX: 310-638-8046WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279

Direct TOLL-FREE accessto our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7 (800/672-7877)

PARTS ORDERING PROCEDURES


DCA-220SSVU — SPECIFICATIONS

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DCA-220SSVU — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

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This Owner's Manual has beendeveloped to provide completeinstructions for the safe andefficient operation of theMQ Power Model DCA-220SSVUWhisperwatt™ Generator.

Before using this generator, ensure that the operatingindividual has read and understands all instructions inthis manual.

Safety precautions should be followed at all times whenoperating this equipment. Failure to read and understand theSafety Messages and Operating Instructions could result ininjury to yourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS

Potential hazards associated with the operation of thisequipment will be referenced with "Hazard Symbols" whichappear throughout this manual, and will be referenced inconjunction with Safety "Message Alert Symbols".

NOTE

DCA-220SSVU — SAFETY MESSAGE ALERT SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform youabout potential hazards that could injure you or others. TheSafety Messages specifically address the level of exposureto the operator, and are preceded by one of three words:DANGER, WARNING, or CAUTION.

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

You COULD be KILLED or SERIOUSLY injured ifyou do not follow directions.

You CAN be injured if you do not follow directions

Gasoline engine exhaust gases containpoisonous carbon monoxide. This gas iscolorless and odorless, and can causeDEATH if inhaled. NEVER operate this

equipment in a confined area or enclosed structure thatdoes not provide ample free flow air.

Gasoline is extremely flammable, andits vapors can cause an explosion ifignited. DO NOT start the engine nearspilled fuel or combustible fluids.DO NOT fill the fuel tank while the engineis running or hot.

DO NOT overfill tank, since spilled fuel could ignite if itcomes into contact with hot engine parts or sparks fromthe ignition system. Store fuel in approved containers, inwell-ventilated areas and away from sparks and flames.NEVER use fuel as a cleaning agent.

Engine components can generate extremeheat. To prevent burns, DO NOT touch theseareas while the engine is running orimmediately after operations. NEVERoperate the engine with heat shields or heatguards removed.

WARNING

DANGER

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, thereexists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even DEATH!

DANGER - ELECTROCUTION HAZARDS


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DCA-220SSVU — SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the engine ON/OFFswitch (MPEC) in the OFF/RESETposition when the generator is not in use.

ALWAYS wear approved respiratoryprotection.

ALWAYS wear approved eye andhearing protection.

Other important messages are provided throughout thismanual to help prevent damage to your generator, otherproperty, or the surrounding environment.

This generator, other property, orthe surrounding environmentcould be damaged if you do notfollow instructions.

NOTE

NEVER tamper with the factory settingsof the engine governor or settings.Personal injury and damage to the engineor equipment can result if operating inspeed ranges above maximum allowable.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,or guards removed. Keep fingers, hands,hair and clothing away from all movingparts to prevent injury.

WARNING - ROTATING PARTS


DCA-220SSVU — RULES FOR SAFE OPERATION

The following safety guidelines should always be used whenoperating the DCA-220SSVU Whisperwatt™ AC Generator.

General Safety:

■ DO NOT operate or service thisequipment before reading this entiremanual.

The operator MUST BE familiar with proper safetyprecautions and operations techniques before usinggenerator.

■ This equipment should not be operated by persons under18 years of age.

■ NEVER operate this equipment without proper protectiveclothing, shatterproof glasses, steel-toed boots and otherprotective devices required by the job.

■ NEVER operate this equipment when notfeeling well due to fatigue, illness or takingmedicine.

■ NEVER operate this equipment under the influence ordrugs or alcohol.

Failure to follow instructions in this manual may lead toserious injury or even DEATH! This equipment is to beoperated by trained and qualified personnel only! Thisequipment is for industrial use only.

DANGER - READ THIS MANUAL!■ ALWAYS check the machine for loosened threads or bolts

before starting.

■ NEVER operate the generator in an explosive atmosphereor near combustible materials. An explosion or fire couldresult causing severe bodily harm or even death.

■ NEVER touch the hot exhaust manifold, muffleror cylinder. Allow these parts to cool beforeservicing engine or generator.

■ High Temperatures – Allow the engineto cool before performing service andmaintenance functions. Contact withhot! components can cause seriousburns.

■ The engine of this generator requires an adequate freeflow of cooling air. NEVER operate the generator in anyenclosed or narrow area where free flow of the air isrestricted. If the air flow isrestricted it will cause seriousdamage to the generator orengine and may cause injuryto people. The generatorengine gives off DEADLYcarbon monoxide gas.

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

■ NEVER run engine without air filter. Severe engine damagemay occur.

■ DO NOT leave the generator running in the manual modeunattended.

■ Refer to the VOLVO Engine Owner's Manual for enginetechnical questions or information.

■ ALWAYS store equipment properly when it is not beingused. Equipment should be stored in a clean, dry locationout of the reach of children.

■ NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damageto the equipment and/or injury to user may result.

■ Manufacturer does not assume responsibility for anyaccident due to equipment modifications. Unauthorizedequipment modification will void all warranties.

■ Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.


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POWERCORD

(POWER ON)

WETHANDS

During operation of this generator, thereexists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connectingequipment to the generator. Make sure power connectingcables are securely connected to the generator’s outputterminals, insufficient tightening of the terminal connectionsmay cause damage to the generatorand electrical shock.

NEVER grab or touch a live powercord with wet hands.

NEVER touch output terminalsduring operation. This is extremelydangerous. ALWAYS stop themachine and place the circuitbreaker in the OFF position whencontact with the output terminals isrequired.

Backfeed to a utility system cancause electrocution and or propertydamage. DO NOT connect to anybuilding's electrical system exceptthrough an approved device or afterbuilding main switch is opened.ALWAYS have a licensed electricianperform the installation

DANGER - ELECTROCUTION HAZARDSGenerator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

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

The following safety recommendations should also befollowed:

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

■ ALWAYS make sure that electrical circuits are properlygrounded per the National Electrical Code (NEC) andlocal codes before operating generator. Severe injury orDEATH! by electrocution can result from operating anungrounded generator.

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

Electrical Safety

■ ALWAYS have a qualified electrician perform thegenerator wiring installation.

■ ALWAYS make sure generator installation is accordancewith the National Electrical Code (NEC) and local codesbefore operating generator.

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

■ NEVER use a extension cord that is frayed or damagedwhere the insulation has been cut.

■ ALWAYS make certain that proper extension cord hasbeen selected for the job. See Table 6.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generatoris being transfer to a load.



Battery Safety

Use the following guidelines when handling the battery:

■ The battery contains acids that cancause injury to the eyes and skin. Toavoid eye irritation, always wear safetyglasses.

■ Use well insulated gloves when picking up the battery.

Maintenance Safety

■ The electrical voltage required to operate the generatorcan cause severe injury or even death through physicalcontact with live circuits. Turn all circuit breakers OFFbefore performing maintenance on the generator.

■ NEVER lubricate components or attempt service on arunning machine.

■ ALWAYS disconnect the NEGATIVE battery terminalbefore performing service on the generator.

■ Follow all Battery Safety Guidelines listed in this manualwhen handleing or servicing the generator.

■ ALWAYS allow the machine a proper amount of time tocool before servicing.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and alwaysreplace broken parts.

■ ALWAYS service air cleaner frequently to prevent enginemalfunction.

To prevent burns, DO NOT touch or open any of the belowmentioned components while the engine isrunning or immediately after operations.Always allow sufficient time for the engineand generator to cool before performingmaintenance.

■ Radiator Cap - Removing the radiator cap while theengine is hot will result in high pressurized, boiling waterto gush out of the radiator, causing severe scalding toany persons in the general area of the generator.

■ Coolant Drain Plug - Removing the coolant drain plugwhile the engine is hot will result in hot coolant gushingout of the coolant drain plug, therefore causing severescalding to any persons in the general area of thegenerator.

■ Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil gushingout of the oil drain plug, therefore causing severescalding to any persons in the general area of thegenerator.

WARNING - BURN HAZARDS■■■■■ 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 workingcondition. Repair or replace all worn cables.

■■■■■ ALWAYS recharge the battery in an vented airenvironment, to avoid risk of a dangerous concentrationof combustible gases.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with your EYES, rinse eyes immediately withplenty of water and contact the nearest doctor or hospitalto seek medical attention.

The risk of an explosion exists when performing serviceon the battery. To avoid severe injury or DEATH:

■■■■■ DO NOT drop the battery. Thereis the possibility of risk that thebattery may explode.

■■■■■ DO NOT expose the battery toopen flames, sparks, cigarettesetc. The battery contains combustible gases and liquids.If these gases and liquids come in contact with a flameor spark, an explosion could occur.

DANGER - EXPLOSION HAZARDS


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Emergencies

■ ALWAYS know the location of thenearest fire extinguisher.

■ ALWAYS know the location of thenearest and first aid kit.

■ ALWAYS know the location of thenearest phone or keep a phone onthe job site, in case of emergencies.

■ ALWAYS have easy access to the phonenumbers of the nearest Ambulance, Doctorand Fire Department. This information willbe invaluable in the case of an emergency.


Check with your local county or state safety towingregulations, in addition to meeting Department ofTransportation (DOT) Safety Towing Regulations, beforetowing your generator.

CAUTION - FOLLOW TOWING REGULATIONS

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place chock blocks underneath wheel to prevent rolling,while parked.

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

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

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all timeswhen towing.

■ Raise and lock trailer wheel stand in up position whentransporting.

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place support blocks underneath the trailer’s bumper toprevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Towing & Transporting Safety

To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailerthat supports the generator and the towing vehicle are ingood operating condition and both units are mechanicallysound.

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

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailercomplies with all local and state safety transportationlaws. Follow the listed Towing & Transporting Safetyguidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating.”

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chains etc.

■ Check the tire air pressure on both towing vehicle andtrailer. Trailer tires should be inflated to 50 psi cold.Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

■ ALWAYS attach trailer’s safety chains to towing vehicleproperly.

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

■ DOT Requirements include the following:Connect and test electric brake operation.Secure portable power cables in cable tray with tiewraps.


The DCA-220SSVU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided foroperator safety and maintenance information. The illustration below and on the preceding page show the decals as theyappear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-220SSVU — GENERATOR DECALS

Figure 2. Generator Decals


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DCA-220SSVU — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)


Figure 4. Typical Generator Grounding Application

DCA-220SSVU — INSTALLATION


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Outdoor Installation

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

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

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

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

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

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

1. Use one of the following wire types to connect thegenerator 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 theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth groundrod should be buried aminimum of 8 ft. into the ground.

When connecting the generatorto any buildings electricalsystem ALWAYS consult witha licensed electrician.

DCA-220SSVU — INSTALLATION

NOTE

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heat excessivelyand possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (suchas concrete) and set firmly on the foundation to isolatevibration of the generator when it is running. The generatormust set at least 6 inches above the floor or grade level (inaccordance to NFPA 110, Chapter 5-4.1). DO NOT removethe metal skids on the bottom of the generator. They are toresist damage to the bottom of the generator and to maintainalignment.

Pay close attention to ventilation when operating thegenerator inside tunnels and caves. The engine exhaustcontains noxious elements. Engine exhaust must be routedto a ventilated area.

CAUTION - EXHAUST HAZARD


DCA-220SSVU — GENERAL INFORMATION

DCA-220SSVU Whisperwatt™ Series FamiliarizationGeneratorThe MQ Power Model DCA-220SSVU is a 176 kW generator(Figure 5) that is designed as a high quality portable (requiresa trailer for transport) power source for telecom sites, lightingfacilities, power tools, submersible pumps and other industrialand construction machinery.Engine Operating PanelThe “Engine Operating Panel” is provided with the following:

■■■■■ Tachometer■■■■■ Water Temperature Gauge■■■■■ Oil Pressure Gauge■■■■■ Charging Ammeter Gauge■■■■■ Fuel Level Gauge■■■■■ Pre-Heat Button■■■■■ Engine Speed Switch■■■■■ Panel Light/Panel Light Switch■■■■■ Auto ON/OFF Engine Controller (MPEC)■■■■■ Coolant Level Alarm Lamp

Generator Control PanelThe “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, 600 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 PanelThe “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■■■■■ Five output terminal lugs (3Ø power)■■■■■ Battery Charger (Optional)■■■■■ Water Heater (Optional)

Open Delta Excitation SystemThe DCA-220SSVU generator is equipped with the state ofthe art "Open-Delta" excitation system. The open deltasystem consist of an electrically independent winding woundamong 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 regulatoris supplied from the parallel connections of A to B, A to D,and C to D. These three phases of the voltage input to thevoltage regulator are then rectified and are the excitationcurrent for the exciter section.When a heavy load, such as a motor starting or a shortcircuit occurs, the automatic voltage regulator (AVR)switches the configuration of the open delta to the seriesconnection of B to C. This has the effect of adding the voltagesof each phase to provide higher excitation to the excitersection and thus better voltage response during theapplication of heavy loads.The connections of the AVR to the AC output windings arefor sensing only. No power is required from these windings.The open-delta design provides virtually unlimited excitationcurrent, offering maximum motor starting capabilities. Theexcitation does not have a "fixed ceiling" and respondsaccording the demands of the required load.EngineThe DCA-220SSVU is powered by a 6 cylinder, water cooled,direct injection, turbocharged VOLVO Model PENTATAD520GE Diesel Engine. This engine is designed to meetevery performance requirement for the generator. ReferenceTable 1 for engine specifications.In keeping with MQ Power's policy of constantly improvingits products, the specifications quoted herein are subject tochange without prior notice.Electric Governor SystemThe electric governor system controls the RPMs of the en-gine. When the engine demand increases or decreases, thegovernor system regulates the frequency variation to ±.25%.Extension CablesWhen electric power is to be provided to various tools orloads at some distance from the generator, extension cordsare normally used. Cables should be sized to allow fordistance in length and amperage so that the voltage dropbetween the generator and point of use (load) is held to aminimum. Use the cable selection chart (Table 6) as a guidefor selecting proper extension cable size.


1

DCA-220SSVU — MAJOR COMPONENTS

Figure 5. Major Components

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NOTE PAGE


1

DCA-220SSVU — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions ofthe DCA-220SSVU Generator Control Panel (Figure 6).

1. Frequency Meter – Indicates the output frequency inhertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the loadis drawing from the generator per leg selected by theammeter phase-selector switch.

3. Ammeter Change-Over Switch – This switch allowsthe AC ammeter to indicate the current flowing to theload connected to any phase of the output terminals, orto be switched off. This switch does not effect thegenerator output in any fashion, it is for current readingonly.

4. Voltage Regulator Control – Allows ±15% manualadjustment of the generator’s output voltage.

5. AC Voltmeter – Indicates the output voltage present atthe U,V, and W Output Terminal Lugs.

6. Voltmeter Change-Over Switch – This switch allowsthe AC voltmeter to indicate phase to phase voltagebetween any two phases of the output terminals or tobe switched off.

7. Main Circuit Breaker – This three-pole, 600A mainbreaker is provided to protect the the U,V, and W OutputTerminal Lugs from overload.

Located behind the generator control panel is the GeneratorControl Box. This box contains some of the necessaryelectronic components required to make the generatorfunction.

The Control Box is equipped with the following majorcomponents:■■■■■ Over-Current Relay■■■■■ Voltage Rectifer (AVR)■■■■■ Starter Relay■■■■■ Current Transformer■■■■■ Voltage Selector Switch■■■■■ Three Phase Circuit Breaker

Figure 6. Generator Control Panel

Remember the overcurrentrelay monitors the currentflowing from the U,V, and WOutput Terminal Lugs to theload.

In the event of a short circuit or over current condition, it willautomatically trip the 600 amp main breaker.

To restore power to the Output Terminal Panel, press thereset button on the overcurrent relay and place the maincircuit breaker in the closed position (ON).

NOTE


Figure 7. Engine Operating Panel

DCA-220SSVU — ENGINE OPERATING PANEL


1

DCA-220SSVU — ENGINE OPERATING PANEL

The definitions below describe the controls and functions ofthe DCA-220SSVU Engine Operating Panel (Figure 7).1. Panel Light – Normally used in dark areas or at night

time. When activated, panel lights will illuminate. Whenthe generator is not in use be sure to turn the panellight switch to the OFF position.

2. Panel Light Switch – When activated will turn on controlpanel light.

3. Oil Pressure Gauge – During normal operation thisgauge be should read between 44 to 73 psi. (303~503kPa). When starting the generator the oil pressure mayread a little higher, but after the engine warms up the oilpressure should return to the correct pressure range.

4. Water Temperature Gauge – During normal operationthis gauge be should read between 165° and 203°F.

5. Charging Ammeter Gauge – Indicates the currentbeing supplied by the engine’s alternator which providescurrent for generator’s control circuits and batterycharging 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’swhen the rated load is applied. In addition a built in hourmeter will record the number of operational hours thatthe generator has been in use.

8. Engine Speed Switch – This switch controls the speedof the engine (low/high).

9. Pre-Heat Button – Press and hold this button for 50seconds to warm (cold weather) the engine glow plugs.

10. Coolant Alarm Lamp – This lamp will illuminate whenthe coolant level falls below a safe operating level.

A. MPEC Control Switch – This switch controls therunning of the unit. If this switch is set to theOFF/RESET position, the unit will not run. When thisswitch is set to the MANUAL position, the generatorwill start immediately.

If the generator is to be connected to a building's ACpower source via a transfer switch (isolation), placethe switch in the AUTO position. In this position thegenerator will monitor the AC line output from thebuilding's power source.

B. Low Oil Pressure – Indicates the engine pressure hasfallen below 15 psi. The oil pressure is detected usingvariable resistive values from the oil pressure sendingunit. This is considered a major fault.

C. High Coolant Temperature – Indicates the enginetemperature has exceeded 239°F. The enginetemperature is detected using variable resistive valuesfrom the temperature sending unit. This is considereda major fault.

D. Overcrank Shutdown – Indicates the unit hasattempted to start a pre- programmed number of times,and has failed to start. The number of cycles andduration are programmable. It is pre-set at 3 cycleswith a 10 second duration. This is considered a majorfault.

E. Overspeed Shutdown – Indicates the engine is runningat an unsafe speed. This is considered a major fault.

F. Engine Running – Indicates that engine is running ata safe operating speed.

If the engine does not engage (start) by the third attempt,the engine will be shutdown by the engine controller’s OverCrank Protection mode. If the engine engages at a speed(RPM's) that is not safe, the controller will shutdown theengine by initializing the Over Speed Protection mode.Also the engine controller will shut down the engine in theevent of low oil pressure, high coolant temperature, lowcoolant level, and loss of magnetic pickup. These conditionscan be observed by monitoring the LED status indicators onthe front of the controller module.

11. 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 faulthas been detected the enginecontroller will evaluate the faultand all major faults will shutdownthe generator. During crankingcycle , The MPEC will attempt tocrank the engine for 10 secondsbefore disengaging.


Output Terminal Familiarization

The “Output Terminal Panel ” (Figure 8) is provided with thefollowing:

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

■■■■■ Three (3) Circuit Breakers @ 50 amps

■■■■■ Two (2) 100V GFCI receptacles @ 20 amp

■■■■■ Two (2) GFCI Circuit Breakers @ 20 amps

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

Output Terminal Panel

The Output Terminal Panel (Figure 8) shown below is locatedon the right-hand side (left from control panel) of the generator.Lift up on the cover to gain access to receptacles and terminallugs.

NOTE Terminal legs “O” and “Ground”are considered bonded grounds.

Figure 8. Output Terminal Panel

DCA-220SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION


1

100 VAC GFCI ReceptaclesThere are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)recepacles provided on the output terminal panel. Thesereceptacles can be accessed in any voltage selector switchposition. Each receptacle is protected by a 20 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) of bothGFCI receptacles is dependent on the load requirements ofthe U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle afterbeing tripped. Pressing the Test Button (See Figure 9) inthe center of the receptacle will check the GFCI function.Both receptacles should be tested at least once a month.

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

Each auxilliary receptacle is protected by a 50 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) on all threereceptacles is dependent on the load requirements of theOutput Terminal Lugs.Turn the voltage regulator control knob (Figure 11) on thecontrol panel to obtain the desired voltage. Turning the knobclockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 10. 120/240V Twist-LockAuxiliary Receptacles

DCA-220SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock(CS-6369) recepacles (Figure 10) provided on the outputterminal panel.These receptacles can only be accessedwhen the voltage selector switch is placed in the single-phase 240/120 position.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic faceplate cover (Figure 12). Un-screw the securing bolts and liftthe plastic terminal cover to gain access to the terminalenclosure.

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


Figure 13. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the OuputTerminal Lugs or the convienience receptacles (Figure 13).Make sure to read the operation manual before attemptingto connect a load to the generator.

To protect the output terminals from overload, a3-pole, 600A main circuit breaker is provided. Make sure toswitch ALL circuit breakers to the OFF position prior tostarting the engine.

DCA-220SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATIONOver Current RelayAn over current relay (Figure 14) is connected to the maincircuit breaker. In the event of an overload, both the circuitbreaker and the over current relay may trip. If the circuitbreaker can not be reset, the reset button on the over cur-rent relay must be pressed. The over current relay is lo-cated in the control box.

Figure 14. Over Current Relay


1

DCA-220SSVU — LOAD APPLICATIONSingle Phase Load

Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage, frequency,and voltage requirements are satisfactorily supplied by thegenerator for operating the equipment.

Generally, the wattage listed on the nameplate of theequipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, asthe wattage is influenced by the efficiency, power factor andstarting system of the equipment.

Motors and motor-drivenequipment draw much greatercurrent for starting than duringoperation.

When connecting ordinary power tools, a capacity of up tothe generating set’s rated output (kW) multiplied by 0.8 canbe used.

If wattage is not given on theequipment's name plate,approximate wattage may bedetermined by multiplyingnameplate voltage by thenameplate amperage.

The power factor of this generator is 0.8. See Table 5 belowwhen connecting loads.

If 3Ø load (kVA) is not given onthe equipment nameplate,approximate 3Ø load outputmaybe determined by multiplyingvoltage by amperage by 1.732.

■■■■■ When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of up tothe generating set’s rated output (kW) can be used.

■■■■■ When connecting a fluorescent or mercury lamp, acapacity 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 currentcapacity.

NOTE

WATTS = VOLTAGE x AMPERAGE

Three Phase Load

When calculating the power requirements for 3-phase poweruse the following equation:

NOTE

An inadequate size connecting cable which cannot carry therequired load can cause a voltage drop which can burn outthe appliance or tool and overheat the cable. See Table 6.

NOTE

Before connecting this generator to any building’s electricalsystem, a licensed electrician must install an isolation(transfer) switch. Serious damage to the building’selectrical system may occur without this transfer switch.

DANGER - ELECTRICAL SYSTEM HAZARDS

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DCA-220SSVU — GENERATOR OUTPUTSGenerator AmperageTables 8 and 9 describe the generator’s current output capa-bility for both 1Ø-phase and 3Ø phase applications.

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CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the voltagechange-over board while the generator is in operation.There exist the possibility of electrocution, electricalshock or burn, which can cause severe bodily harmor even death!

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Maximum AmpsTable 10 shows the maximum amps the generator can pro-vide. DO NOT exceed the maximum amps as listed.

How to Read the Output Terminal Gauge.The AC ammeter and AC voltmeter change-over switcheson the control panel DO NOT effect the generator output.They are provided to help observe how much power is beingsupplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø,240V operation (See Figures 17 and18), place the AC Volt-meter Change-Over Switch (See Figures 19 and 20) to theW-U position and the AC Ammeter Change-Over Switch(Figure 19) to the U or W position to read the output on theselected leg.

Figure 16. Voltage Change-Over Board 240V Configuration

Figure 17. AC VoltmeterChange-Over Switch

Figure 18. AC Voltmeter Gauge(Volt reading on W-U Lug)

Figure 20. AC Ammeter(Amp reading on U lug)

Figure 19. AC AmmeterChange-Over Switch

The ammeter gauge will onlyshow a reading when theOutput Terminal Lugs areconnected to a load and in use.

NOTE

DCA-220SSVU — GENERATOR OUTPUTS/ GAUGE READING

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UVWO Terminal Output VoltagesVarious output voltages can be obtained using the UVWOoutput terminal lugs. The voltages at the terminals are de-pendent on the placement of the jumpers plates (6) on theVoltage Change-Over Board and the adjustment of theVoltage Regulator Control Knob.Remember the voltage change-over board determines therange of the output voltage and can be configured in twodifferent positions that provide 6 different output voltages atthe UVWO output terminals. The generator is shipped fromthe factory in the 240V configuration. The voltage regulator(VR) allows the user to increase or decrease the selectedvoltage.

3Ø-240V UVWO Terminal Output Voltages1. Jumper the voltage change-over board for 240V operation

as shown in Figure 21.

Figure 22. UVWO Terminal Lugs 3Ø-240V Connections

2. Connect the load wires to the UVWO terminals as shownin Figure 22.

3. Turn the voltage regulator knob (Figure 23) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output. Use voltage regulatoradjustment knob whenever fine tuning of the outputvoltage is required

Figure 23. Voltage Regulator Knob

1Ø-240V UVWO Terminal Output Voltages1. Make sure the voltage change-over board is jumpered

for 240V operation as shown in Figure 21 .





for 240V operation as shown in Figure 21.


DCA-220SSVU — OUTPUT TERMINAL PANEL CONNECTIONS


1

DCA-220SSVU — OUTPUT TERMINAL PANEL CONNECTIONS


3Ø-480V UVWO Terminal Output Voltages1. Jumper the voltage change-over board for 480V operation

as shown in Figure 26. This configuration uses 6 jumperplates in 3 different positions. Remember there are 2jumper plates at every position. Every jumper plate mustbe used.









Figure 29. UVWO Terminal Lugs 1Ø-277V ConnectionsALWAYS make sure that the

connections to the UVWOterminals are secure and tight.The possibility of arcing exists,that could cause a fire.

NOTE



DCA-220SSVU — PRE-SETUP

Figure 30. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil isclean. If the oil is not clean, drain the oil by removing the oildrain plug, and refill with the specified amount of oil as outlinedin the Volvo Engine Owner's Manual. Oil should be warmbefore draining.

Other types of motor oils may be substituted if they meetthe following requirements:

■■■■■ API Service Classification CC/SC■■■■■ API Service Classification CC/SD■■■■■ API Service Classification CC/SE■■■■■ API Service Classification CC/SF

Circuit Breakers

To protect the generator from an overload, a 3-pole, 600 amp,main circuit breaker is provided to protect the U,V, and WOutput Terminals from overload. In addition two single-pole,20 amp GFCI circuit breakers are provided to protect theGFCI receptacles from overload. Three 50 amp load circuitbreakers have also been provided to protect the auxiliaryreceptacles from overload. Make sure to switch ALL circuitbreakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but DO NOT overfill. Make sure the generator is level.and verify that the oil level is maintained between the twonotches (Figure 30) on the dipstick. See Table 9 for properselection of engine oil.

Figure 31. Internal Fuel Tank System

Refilling the Fuel System

Fuel Check

This generator has an internal fuel tank located inside thetrailer frame and may also be equipped with an environmentalfuel tank (Figure 31). ALWAYS fill the fuel tanks with cleanfresh #2 diesel fuel. DO NOT fill the fuel tanks beyond theircapacities.

Pay attention to the fuel tank capacity when replenishingfuel.The fuel tank cap must be closed tightly after filling.Handle fuel in a safety container. If the container does nothave a spout, use a funnel. Wipe up any spilled fuelimmediately.

ONLY properly trained personel who have read andunderstand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

Fuel spillage on a hot engine can cause a fire or explosion.If fuel spillage occurs, wipe up the spilled fuel completelyto prevent fire hazards. NEVER smoke around or near thegenerator.

DANGER - EXPLOSION/FIRE HAZARDS


1

DCA-220SSVU — PRE-SETUPRefueling Procedure:

1. Level Tanks – Make sure fuel cells are level with theground. Failure to do so will cause fuel to spill from thetank before reaching full capacity (Figure 32).

Figure 32. Only Fill on Level Ground

ONLY! use #2 diesel fuel whenrefueling.

NOTE

3. NEVER overfill fuel tank – It is important to read thefuel gauge when filling trailer fuel tank. DO NOT wait forfuel to rise in filler neck (Figure 34).

Figure 34. Full Fuel Tank

Figure 35. Fuel Expansion

3. Open cabinet doors on the “right side” of the generator(from generator control panel position). Remove fuel capand fill tank (Figure 33).

Figure 33. Fueling the Generator

ALWAYS place trailer on firm level ground before refuelingto prevent spilling and maximize the amount of fuel thatcan be pumped into the tank.


Diesel fuel and its vapors are dangerousto your health and the surroundingenvironment. Avoid skin contact and/orinhaling fumes.

WARNING - RESPIRATORY HAZARDS

DO NOT OVER-FILL fuel system. Leave room for fuelexpansion. Fuel expands when heated (Figure 35).



Coolant (ISUZU Antifreeze/Summer Coolant/Water)VOLVO recommends VOLVO antifreeze/summer coolant foruse in their engines, which can be purchased in concentrate(and mixed with 50% demineralized water) or pre-diluted.See the VOLVO Engine Owner's Manual for further details.

Day-to-day addition of coolant is done from the recoverytank. When adding coolant to the radiator, DO NOT removethe radiator cap until the unit has completely cooled. SeeTable 12 for engine, radiator, and recovery tank coolantcapacities. Make sure the coolant level in the recovery tankis always between the "H" and the "L" markings.

Operation Freezing Weather

When operating in freezing weather, be certain the properamount of antifreeze (Table 13) has been added.

Cleaning the Radiator

The engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the machine isdangerous, so clean only with the engine turned off and thenegative battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it inaccordance with the VOLVO Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with the VOLVOEngine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15mm (Figure 36) when depressed with the thumb as shownbelow.

Figure 36. Fan Belt Tension

DCA-220SSVU — PRE-SETUP

When the antifreeze is mixed withwater, the antifreeze mixing ratiomust be less than 50%.

NOTE

If adding coolant/antifreeze mix to theradiator, DO NOT remove the radiator capuntil the unit has completely cooled. Thepossibility of hot! coolant exists whichcan cause severe burns.


NEVER place hands nearthe belts or fan while thegenerator set is running.

CAUTION - ROTATING PARTS

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DCA-220SSVU — PRE-SETUPWhen connecting battery do the following:

1. NEVER connect the battery cables to the batteryterminals when the MPEC Control Switch is in eitherthe MANUAL position. ALWAYS make sure that the MPECControl Switch is in the OFF/RESET position whenconnecting the battery.

2. Place a small amount of battery terminal treatmentcompound around both battery terminals. This will ensurea good connection and will help prevent corrosion aroundthe battery terminals.

Figure 37. Battery Connections

ALWAYS disconnect the negative terminal FIRST andreconnect negative terminal LAST.

Inadequate battery connections may cause poor startingof the generator, and create other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. Whenan inverted circuit connection takes place, the circuit will bein short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of waterinto the alternator can cause corrision and damage thealternator.

Wiring

Inspect the entire generator for bad or worn electrical wiringor connections. If any wiring or connections are exposed(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections forwear and tightness. Tighten all hose clamps and check hosesfor leaks.

If any hose (fuel or oil) lines are defective replace themimmediately.

If the battery cable is connectedincorrectly, electrical damage to thegenerator will occur. Pay closeattention to the polarity of thebattery when connecting thebattery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level are notproperly maintained. Add only distilled water whenreplenishment is necessary.

DO NOT over fill. Check to see whether the battery cablesare loose. Poor contact may result in poor starting ormalfunctions. Always keep the terminals firmly tightened.Coating the terminals with an approved battery terminaltreatment compound. Replace battery with onlyrecommended type battery. The battery type used in thisgenerator is BCI Group 27.

The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68° F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead and needs to be recharged or replaced.

Before charging the battery with an external electric source,be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 37) are properlyconnected to the battery terminals as shown below. The RedCable is connected to the positive terminal of the battery,and the Black Cable is connected to the negative terminalof the battery.

CAUTION - BATTERY SERVICING SAFETY

CAUTION - BATTERY SERVICING SAFETY


5. Verify that the Engine Runningstatus LED on the MPEC unit(Figure 44) is ON (lit) after theengine has been started.

Figure 44. Engine Running LED (ON)

Starting (Manual)

1. In cold weather conditions, press and hold the pre-heatbutton (Figure 40) for at least 50 seconds to warm theengine glow plugs.

Figure 42. MPEC Control Switch(Manual Position)

DCA-220SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

The engine's exhaust contains harmful emissions.ALWAYS have adequate ventilation when operating.Direct exhaust away from nearby personnel.

Before Starting

Figure 39. Engine Enclosure Doors

1. Place the main, G.F.C.I., and aux. circuit breakers(Figure 38) in the OFF position prior to starting the engine.

Figure 38. Main, Aux. and GFCICircuit Breakers (OFF)

2. Make sure the the voltage change-over board hasbeen configured for the desired output voltage.

3. Connect the load to the receptacles or the outputterminal lugs as shown in Figure 13. These loadconnection points can be found on the output terminalpanel and the output terminal panel’s hard wire hookuppanel.

4. The output terminal lugs are protected by a plastic cover.Remove this cover to gain access to the terminals.Tighten terminal nuts securely to prevent load wires fromslipping out.

5. Close all engine enclosure doors (Figure 39).

CAUTION - LETHAL EXHAUST HAZARD

Figure 42. Pre-Heat Button

4. Once the engine starts, let it engine run for 1-2 minutes.Listen for any abnormal noises. If any abnormalitiesexists shutdown the engine and correct the problem.If the engine is running smoothly, place the enginespeed switch (Figure 43) in the “HIGH” (up) position.

3. Once the engine glow plugs have been warmed, placethe MPEC Control Switch in the MANUAL position tostart the engine (Figure 42).

2. Place the engine speed switch (Figure 41) in the “LOW ”(down) position.

Figure 41. Engine Speed Switch (Low)

Figure 43. Engine Speed Switch (High)

NEVER! manually start the engine with the main, GFCIor auxiliary circuit breakers in the ON (closed) position.

WARNING - STARTING THE GENERATOR


1

DCA-220SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

Figure 47. Voltage Adjust Control Knob

Figure 48. Ammeter(No Load)

8. The ammeter (Figure 48) willindicate zero amps with no loadapplied. When a load is applied, theammeter will indicate the amount ofcurrent that the load is drawing fromthe generator.

7. The generator's AC-voltmeter (Figure 47) will display thegenerator’s output in VOLTS. If the voltage is not withinthe specified tolerance, use the voltage adjustmentcontrol knob (Figure 47) to increase or decrease thedesired voltage.

Figure 46. Voltmeter

Figure 45. Frequency Meter (Hz)

6. The generator's frequency meter (Figure 45) should bedisplaying the 60 cycle output frequency in HERTZ.

Figure 51. EngineTachometer Gauge

11. The tachometer gauge (Figure 51)will indicate the speed of the enginewhen the generator is operating.Under normal operating conditionsthis speed is approximately 1600RPM’s.

10. The coolant temperature gauge(Figure 50) will indicate thecoolant temperature. Undernormal operating conditions thecoolant temperature should bebetween 165 and 203 degreesFahrenheit (Green Zone).

Figure 50. CoolantTemperature Gauge

9. The engine oil pressure gauge(Figure 49) will indicate the oilpressure of the engine. Undernormal operating conditions the oilpressure is approximately 44 to 73psi. (303~503 kPa). When startingthe genera Figure 49. Oil

Pressure Gauge

Figure 52. Main, Aux. and GFCICircuit Breakers (ON)

12. Place the main, GFCI, and aux. circuit breakers in theON position (Figure 52).

13. Observe the generator's ammeter(Figure 53) and verify it reads theanticipated amount of current withrespect to the load. The ammeterwill only display a current reading ifa load is in use.

Figure 53. Ammeter(Load)

14. The generator will run until manually stopped or anabnormal condition occurs.


1. Perform steps 1 through 5 in the Before Starting sectionas outlined in the Manual Starting Procedure.

2. Place the engine speed switch (Figure 54) in the HIGHposition

4. Continue operating the generator as s outlined in theManual Start-up procedure (start at step 5).

Figure 55. MPEC Control Switch (AUTO)

When the generator is set in theAUTO mode, the generator willautomically start in the event ofcomercial power falling below aprescribed level by means of acontact closure that is generatedautomatically by a transfer switch.

NOTE

Starting (Auto Mode)

Before connecting this generator to anybuilding’s electrical system, a licensedelectrician must install an isolation(transfer) switch. Serious damage to thebuilding’s electrical system may occurwithout this transfer switch.

DANGER - ELECTRICAL SYSTEM HAZARDS

When connecting the generator to a isolation (transfer)switch, ALWAYS have power applied to the generator'sinternal battery charger. This will ensure that the enginewill not fail due to a dead battery.

CAUTION - BACKUP GENERATOR USE

When running the generator in the AUTO mode, rememberthe generator can start up at any time without warning.NEVER attempt to perform any maintenance when thegenerator is in the auto mode.

WARNING - AUTO MODE MAINTENANCE

DCA-220SSVU — GENERATOR START-UP PROCEDURE (AUTO MODE)

When the MPEC Control Switchis placed in the AUTO position,the engine glow plugs will bewarmed and the engine will startautomatically.

NOTE

When starting generator in AUTO mode use the "ManualStart-up" procedure except where noted (see below).

CAUTION - ENGINE SPEED SWITCH

The Engine Speed Switch must be set to the “High”position when running in the Auto-Start mode. Failing toset the switch in the proper position can result in damageto your generator when it turns on.

3. Place the MPEC Control Switch (Figure 55) in the AUTOposition

Figure 54. Engine Speed Switch (High)


1

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakersas shown in Figure 38 to the OFF position.

2. Place the engine speed switch (Figure 56) in the “LOW ”(down) position.

Figure 57. MPEC Control Switch (Off/Reset)

5. Verify that the all status LED on the MPEC displayare OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening ofcomponents that may have occured during operation.

Emergency Shutdown Procedure

1. To shut-down the engine in the event of an emergency,switch the MAIN, GFCI and LOAD (Figure 38) circuitbreakers to OFF position.

2. Place the MPEC Control Switch switch (Figure 57) tothe OFF/RESET position.

DCA-220SSVU — GENERATOR SHUT-DOWN PROCEDURES

3. Let the engine cool by running it at low speed for 3-5minutes with no load applied.

4. Place the MPEC Control Switch (Figure 57) to theOFF/RESET position.

Figure 56. Engine Speed Switch (Low)

NEVER stop the engine suddenly except in an emergency.

WARNING - SHUTTING DOWN THE GENERATOR


DCA-220SSVU — MAINTENANCE

Service Daily

If the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber and high fuel consumption. Change air cleanermore frequently if these conditions exists.Fuel Addition

Add diesel fuel (the grade may vary according to seasonand locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulatein the bottom of the tank. Occasionally inspect the fueltank for water contamination and drain the contents ifrequired.

During cold weather, the more empty volume inside thetank, the easier it is for water to condense. This can bereduced by keeping the tank full with diesel fuel.

General Inspection

Prior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks. Use Table 14 as a general maintenanceguideline Engine Side (Refer to the Engine InstructionManual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean theheavy duty paper element with light spray of compressedair. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the aircleaner element is clogged, air intake restriction becomesgreater and the dust indicator signal shows RED meaningthe element needs changing or service. After changing theair element, press the dust indicator button to reset theindicator.

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Generator Storage

For longe term storage of the generator the following isrecommended:

Fill the fuel tank completely. Treat with a fuel stabilizerif necessary.

Completely drain the oil from the crankcase and refill ifnecessary with fresh oil.

Clean the entire generator, internal and external.

Cover the generating set and store in a clean, dry place.

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up andplace on blocks so tires do not touch the ground or blockand completely remove the tires.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and atthe lower part of the radiator and drain coolant. Open theradiator cap while draining. Remove the overflow tankand drain.

Check hoses for softening and kinks. Check clamps forsigns of leakage.

Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DO NOTclean radiator core with any objects, such as ascrewdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant as recommended by the enginemanufaturer.

Close radiator cap tightly.

Air Removal

If air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure. See the VOLVO EngineManual for details.To restart after running out of fuel, turn the switch to the“ON” position for 15-30 seconds. Try again, if needed. Thisunit is equipped with an automatic air bleeding system.

Check Oil Level

Check the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 31.

Replacing Oil Filter

Remove the old oil filter.

Apply a film of oil to the gasket on the new oil filter.

Install the new oil filter.

After the oil cartridge has been replaced, the engine oilwill drop slightly. Run the engine for a while and checkfor leaks before adding more oil if needed. Cleanexcessive oil from engine.

Allow engine to cool when flushing outradiator. Flushing the radiator while hotcould cause serious burns from water orsteam.


Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500hours or so.

Loosen the drain plug at the lower top of the fuel filter.Drain the fuel in the fuel body together with the mixedwater. DO NOT spill the fuel during disassembly.

Vent any air.

Cleaning the Fuel StrainerClean the fuel strainer if it contains dust or water. Removedust or water in the strainer cap and wash it in gasoline.Securely fasten the fuel strainer cap so that fuel will notleak. Check the fuel strainer every 200 hours of operation oronce a month.



To ensure adequate startingcapability, always have powerapplied to the generator'sinternal battery charger.

NOTE

Figure 56. DCA-45SIU2 Battery Charger &Jacket Water Heater Power Connections

Jacket Water Heater and Internal Battery Charger120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,20 amp input receptacles located on the output terminalpanel.

The purpose of these receptacles is to provide power viacommercial power to the jacket water heater and internalbattery charger.

These receptacles will ONLY function when commercialpower has been supplied to them (Figure 58). To applycommercial power to these receptacles, a power cord ofadequate size will be required (See Table 6).

When using the generator in hot climates there is no reasonto apply power to jacket water heater. However, if thegenerator will be used in cold climates it is always a goodidea to apply power to the jacket water heater at all times. Toapply power to the jacket water heater simply apply power tothe jacket water heater receptacle via commercial powerusing an power cord of adequate size.

If the generator will be used daily, the battery should normallynot require charging. If the generator will be idle (not used)for long periods of time, apply power to the battery chargerreceptacle via commercial power using an power cord ofadequate size.


1

DCA-220SSVU — TRAILER MAINTENANCE7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches(10,12,14, etc.), and the width in millimeters(175,185,205, etc.). The tire diameter must match thediameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’saxle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim mustmatch the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.Always use a torque wrench to tighten down the lugnuts. See Table 16 and Figure 59 for lug nut tighteningand sequence.

13. Axle - Indicates the maximum weight the axle can sup-port in pounds, and the diameter of the axle expressedin inches. Please note that some trailers have a doubleaxle. This will be shown as 2-6000 lbs., meaning twoaxles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shockstransmitted through the wheels. Types of suspensionused are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle.

16. Application - Indicates which units can be employedon a particular trailer.

Trailer Maintenance

This section is intended to provide the user with generictrailer service and maintenance information. The service andmaintenance guidelines referenced in this section refer to awide range of trailers.

Remember periodic inspection of the trailer will ensure safetowing of the generator and will prevent personal injury anddamage to the equipment.

The definitions below describe some of the major componentsof a typical trailer that would be used with the DCA-220SSVUWhisperwatt™ Generator.

1. Fuel Cell - Provides an adequate amount of fuel for theequipment in use. Fuel cells must be empty when trans-porting equipment.

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is themaximum number of pounds the trailer can carry, in-cluding the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch tothe rear bumper (reflector).

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum poundrequirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.


DCA-220SSVU — TRAILER MAINTENANCEHydraulic Surge BrakesHydraulic surge brakes (Figure 59) should not require anyspecial attention with the exception of routine maintenancesuch as shoe and lining replacement. Brake lines should beperiodically checked for cracks, kinks, or blockage.

Figure 59. Hydraulic Brake Components

BrakesTrailer brakes should be inspected the first 200 miles ofoperation. This will allow the brake shoes and drums to seatproperly. After the first 200 mile interval, inspect the brakesevery 3,000 miles. If driving over rough terrain, inspect thebrakes more frequently.

Figure 59 displays the major hydraulic surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps 1through 8 and Table 15 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jackstands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slotat the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate thestar wheel of the adjuster assembly to expand the brakeshoes.

5. Adjust the brake shoes outward until the pressure of thelining against the wheel drum makes the wheel difficultto turn.

6. Adjust, rotate the star wheel in the opposite directionuntil the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer tothe ground.

8. Repeat steps 1 through 7 on the remaining brakes.

ActuatorHydraulic surge braking requires the installation of an actuatorat the tongue of the trailer. Remember the surge or push ofthe trailer toward the tow vehicle automatically synchronizesthe trailer brakes with the tow vehicle brakes. As the trailerpushes against the tow vehicle the actuator telescopestogether and applies force to the master cylinder, supplyinghydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to makesure that it is functioning correctly. Never use an undersizeactuator.

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Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot!. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint thecauses and solutions of tire wear problems.

SuspensionThe leaf suspension springs and associated components(Figure 60) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 17.

Figure 60. Major Suspension Components

DCA-220SSVU — TRAILER MAINTENANCE

DO NOT attempt to repair or modify a wheel. DO NOTinstall in inner tube to correct a leak through the rim. If therim is cracked, the air pressure in the innertube may cause pieces of the rim toexplode (break off) with great force andcause serious eye or bodily injury.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS wear safety glasses whenremoving or installing force fitted parts.Failure to comply may result in seriousinjury.

CAUTION - EYESIGHT HAZARD

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SHACKLE BOLT

SPRING EYE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT-BOLT ASSEMBLY.

SHOULDER TYPE

SHACKLE BOLT05-XAM03-NIM


NEVER use an pneumatic airgun to tighten wheel lug nuts.

Figure 61. Wheel Lug NutsTightening Sequence

DCA-220SSVU — TRAILER MAINTENANCE

NOTE

Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure for at

whisperwatt series model dca-220ssvu · 2016. 12. 28. · page 8 — dca-220ssvu— operation and...

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