No.C18443 01504 E INSTRUCTION MANUAL ALTERNATING CURRENT GENERATING SETS DCA-220,-400ESEI IMPORTANT: READ AND UNDERSTAND THIS MANUAL CAREFULLY BEFORE USE OF THIS MACHINE. KEEP THIS MANUAL FOR YOUR FUTURE REFERENCE. 2-8-5 Nihonbashi-horidomecho, Chuo-ku, Tokyo, 103-8566 Japan
CONTENTS SAFETY PRECAUTIONS FOR GENERATORS... 2 1. DCA series... 8 1-1 General... 8 1-2 Machine structure... 8 1-3 Machine appearance and internal component devices... 8 1-4 Control switches and meters... 10 1-4-1 Engine start/stop controls... 10 1-4-2 Engine indicators... 12 1-4-3 Generator controls and indicators... 18 1-5 Noise... 18 2. Transportation, storage and installation... 19 2-1 Safety precautions for transportation, storage and installation... 19 2-2 Transportation... 20 2-3 Storage... 20 2-3-1 Storage method... 20 2-3-2 Preparing for operation... 21 2-4 Installation... 22 2-4-1 Installation... 22 2-4-2 Checking after installation... 25 3. Operation... 27 3-1 Safety precautions for operation... 27 3-2 Connecting the load... 29 3-2-1 Precautions in connecting the load... 29 3-2-2 Non-liner and sensitive loads... 29 3-2-3 Selection of cables... 30 3-2-4 connecting the load... 31 3-3 Before starting... 32 3-3-1 Checkup before start-up... 32 3-3-2 Instruction for Fuel Source Changeover Device (Three-Way valve)... 34 3-4 Starting... 34 3-5 During operation... 36 3-6 Stopping... 36 3-6-1 Stopping method... 36 3-6-2 Emergency stop... 36 3-6-3 Protection device... 36 4. Remote control... 38 4-1 Outline of the operation... 38 4-2 Indications and operation device... 38 4-3 Local operation (operation by the starter switch)... 38 4-4 Remote operation... 38 4-4-1 Setting of operation switches... 38 4-4-2 Starting... 38 4-4-3 Stopping... 39 4-5 Cautions of operation... 39 4-6 Protective devices... 39 4-6-1 Protective devices for remote operation... 39 4-7 Fault diagnosis... 40 4-7-1 Starting failure (causes)... 40 4-7-2 Abnormality during operation (causes)... 40 4-8 Attached time chart... 41
5. Fuel, coolant and lubricants... 42 6. Periodic checkup and maintenance... 44 6-1 Safety precautions for periodic checkup and maintenance... 44 6-2 Periodic chechup... 45 6-2-1 Maintenance schedule... 45 6-2-2 Checking/every 250 hours... 46 6-2-3 Checking/every 500 hours... 47 6-2-4 Checking/every 1000 hours... 50 6-2-5 Table of periodical maintenance and checking... 51 7. Troubleshooting... 52 8. Principal data... 53 8-1 Readings on gauges... 53 8-2 Setting of switches... 53 8-3 Reference conditions... 53 8-4 Limitations... 53 8-5 General specifications... 54 8-6 Conversion list of SI units into UK/US units... 55
FOREWORD We are very thankful for your special choice of our MACHINE in the market. E Please read this manual carefully and understand for proper use this machine. Please keep this manual at your prescribed location where operator can always take this manual. If you have any question or problem on this operation, please contact your nearest Distributors. Pay special attention to statements preceded by the following word. DANGER: indicates an imminently hazardous situation which, if not heeded, will result in death or serious injury. WARNING: indicates a potentially hazardous situation which, if not heeded, could result in death or serious injury. CAUTION: indicates a hazardous situation which, if not heeded, may result in minor or moderate injury or damage to the machine. [ NOTE ]: indicates useful information for the machine operations. - 1 -
SAFETY PRECAUTIONS FOR GENERATORS In order to ensure safe operation, the following symbols are used for explanation of the machine operation. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. WARNING: This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. [ NOTE ]: This symbols show handling precautions for effective operation and many years of satisfactory operation. Some of the items shown by CAUTION may also cause death or serious injury. Be sure to observe all the items, as they are important for safe operation. If the machine is used by an outsider, you are requested to explain him correct handling and advise him to read this instruction manual carefully. Do not modify the machine at your discretion, as it affects the safety, performance or the life of the machine. If the machine is modified or it is used incorrectly against this manual or unauthorized parts are used, the warranty of manufacturer will become invalid. - 2 -
SAFETY LABEL Safety labels are attached to the following positions of the machine. Keep these safety labels clean at all times. When safety labels are spoiled or lost, contact distributor or our office specifying the nameplate No. shown below and ask for new ones. E Parts name Parts number CAUTION : Instruction manual B9111 0230 DANGER : Electric shock B4510 0250 WARNING : Fire/explosion B9045 0100 CAUTION : Burn B9111 0240 CAUTION : Moving parts B9040 0050 CAUTION : Emergency stop B9044 0000 CAUTION : Hot coolant/battery B9041 0020 CAUTION : Engine fan B9040 0060 WARNING : Falling B9111 0250 WARNING : Engine exhaust B9042 0020 CAUTION: Instruction manual Do not use machine before reading the instruction manual. Do access to machine in accordance with the instruction manual when machine is in fault. Do consult to authorized person for repair or maintenance to avoid incidents. - 3 -
DANGER: ELECTRIC SHOCK can kill. Do not touch the output terminals during operation to prevent decease due to electric shock. Never touch the output terminals during operation. If your hands or the machine are wet, it will result in a death or serious injury. When a wiring work is required, be sure to turn OFF the circuit breaker and stop the machine. Keep the output terminal cover closed and the terminal bolts tightened while the machine is running. A low voltage is generated even when the machine is in low speed idle operation. Be sure to stop the machine completely. Do not touch the electrical parts in the machine during operation, as it may lead to death due to electric shock. Always close the control panel and tighten the fixing bolts before operating the machine. Always close the side door and lock it before operating the machine. When opening the control panel for voltage selection, etc., turn OFF the circuit breaker and stop the machine. DANGER: ELECTRIC SHOCK by leak can kill. CAUTION: MOVING PARTS can cause severe injury. Improper grounding may lead to death due to electric shock. Be sure to execute the grounding of the machine and the load according to the local rule. Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) Be sure to close the door and lock it during operation. When the door needs to be opened during operation, do not get your hands and head in the machine to prevent them from being caught in the machine which may lead to injury. When making check or maintenance of the machine, be sure to stop the machine in advance. - 4 -
WARNING: DIESEL FUEL can cause fire or explosion. CAUTION: HOT COOLANT can cause severe scalds. E Fuel and oil are flammable. Incorrect handling results in danger of ignition or fire. When fuel needs to be supplied to the machine, be sure to stop the engine. Refrain from smoking. Keep the machine away from fire. Do not leave flammable objects (paper, wood chips, etc.) and hazardous objects (oil, powder, etc.) near the machine. Wipe off spilt fuel and oil. If the radiator cap is opened while the water temperature is high, steam or hot water will spout out. During operation or immediately after stopping the machine, do not open the radiator cap while the water temperature is high. When cooling water needs to be checked or supplied, wait until the engine is cooled (50 C or less as measured with the water temperature gauge). CAUTION: HOT PARTS can burn skin. CAUTION: Battery. High temperature units are located in the machine. (Note that these units are very dangerous if they are used incorrectly.) Be sure to close the door and lock it during operation. If the door needs to be opened during operation, do not get your hands and head in the machine to prevent unexpected burns. When making check or maintenance of the machine, be sure to stop the machine. The bonnet is still hot even after the machine is stopped. Be careful until the engine is completely cooled. CAUTION: ENGINE EXHAUST can kill. Insufficient ventilation may lead to death due to lack of oxygen or poisoning by exhaust gases. Do not use the machine in a place of poor ventilation or in a place where exhaust gases stays. Do not use the machine indoors or in storehouse, tunnel, ship hold, tank, etc. of poor ventilation. If it becomes necessary to use the machine in the above places, the exhaust pipe should be extended to a well ventilated place. In this case, use a ventilator to ensure proper ventilation. Do not direct the exhaust outlet to nearby pedestrians and houses. Battery generates flammable gases. Improper handling may lead to explosion or serious injury. Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. When connecting a booster cable, do not jumper the terminals (+ and -). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. For maintenance of the machine, disconnect the ground cable on the ground side. The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. In the worst case, it will put out your eyes. For checking or handling of the battery, be sure to stop the engine and turn OFF the battery switch in advance. - 5 -
CAUTION: Operator. CAUTION: Noise. Do not operate the machine if operator is tired too much or drinks some alcohol or take some drugs. Otherwise, it may cause unexpected accidents or injury. During checking or maintenance, be sure to put on suitable clothes and protectors. Do not put on baggy clothes, necklace, etc., because they are easily caught by projections which may cause injuries. This machine generates large noise if the door is open. Surrounding to large noise may cause hearing trouble. Close and lock the door during operation. If opening the door is necessary during operation, be sure to put on the ear protector. CAUTION: Connection to house wiring. CAUTION: Transportation. Before connecting this machine to any building s electrical system, a licensed electrician must install an isolation(transfer) switch. Serious injury or death may result without this transfer switch. Do not lift the machine at the support hook or the ladder because it is not strong enough for lifting and may cause a falling accident. When lifting the machine, use the hanger located at the roof center. Keep out under the lifted machine. Do not lift or do not transport the machine during operation, as it may cause damage to the fan or serious trouble. When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side. - 6 -
SAFETY LABEL Model DCA-400ESEI E This instruction manual describes how to handle the machine with a view to promising safety run, maximum efficiency and long durability. Read the manual attentively before starting the machine operation for correct handling, operation and appropriate maintenance from the beginning. The maintenance schedule consists of a procedure of keeping the machine in good condition. For the user, keep the manual carefully for machine operation and maintenance according to the instructions. Observe all the safety precautions including ones stated in the manual. Entrust the repair to trained personnel of Denyo or its distributor who are capable of contacting us as required. Parts number 1 DANGER: Electric shock 2 WARNING: Fire/explosion 3 CAUTION: Burn 4 CAUTION: Moving parts 5 CAUTION: Instruction manual 6 CAUTION: Emergency stop 7 CAUTION: Hot coolant/battery 8 CAUTION: Engine fan 9 WARNING: Falling 10 WARNING: Engine exhaust When consulting us, specify the model and serial number indicated on the nameplate. For data not specified in the manual, see Principal data. The company reserves the right to make changes without prior notice. - 7 -
SAFETY PRECAUTION: The user must carry out all safety precautions stated in the manual. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. 1. DCA SERIES 1-1 General DCA series generator is intended for generating power source where there is no power source. For further details, see 7 Principal data. 1-2 Machine structure The generator which is directly driven by Isuzu water-cooled diesel engine is mounted on the common frame along with control equipment, radiator, battery, fuel tank and other auxiliary equipment. The altogether is covered by a sound-insulated steel bodywork. See Fig. 1. 1-3 Machine appearance and internal component devices There are the hanger at the center on the top surface and rope hanger on its both sides. When lifting the machine, use the hanger. Do not resort to winding rope because it is not strong enough. See Fig. 2. The engine cooling water refilling port and fuel refilling port are located on the top surface of the machine. The drain plugs for engine oil, cooling water and fuel are located at the base side under the machine. Tags of their respective names are attached there. Fig. 1 Model DCA-400ESEI Parts number 1. AC generator 2. Diesel engine 3. Control box 4. Fuel tank 5. Radiator 6. Battery 7. Muffler 8. Intercooler - 8 -
Fig. 2 Model DCA-400ESEI E Parts number Parts number 1. Hanger 8. Cooling air intake port 2. Rope hanger 9. Cooling air exhaust port 3. Radiator cooling water refilling port cover 10. Side door 4. Fuel tank refilling port cover 11. Environment base drain 5. Fuel drain plug 12. Three-way valve 6. Oil drain plug 13. Emergency stop button 7. Engine exhaust port 14. PE earthing terminal - 9 -
1-4 Control switches and meters The control switches and meters are located inside the door having a window on the rear of the machine. The control panel is mounted on the bodywork with hinges and is fastened by screws. Loosening the screws has access to repairing or replacing electrical parts in the control box. 1-4-1 Engine start/stop controls Fig. 3 Model DCA-400ESEI Parts number Parts number 1. Frequency meter 8. Panel light switch 2. Ac ammeter 9. Panel light 3. Ammeter change over switch 10. Engine indicator 4. Ac voltmeter 11. Starter switch 5. Voltage regulator 12. Preheat lamp 6. Circuit breaker (for main) 13. Terminal block (for remote control) 7. Earth leakage relay 14. Emergency stop button 15. Electronic governor controller (in the control box) - 10 -
1. Starter switch E The switch is 3-position switch which can be operated with its specific key only. 1) OFF This switch should be set in this position unless the machine is in operation. The key can be inserted or pulled out in this position. 2) RUN This switch should be set in this position when the machine is in operation. In this position, the preheating system is energized. When the preheat indicator lamp lights up, reaching the set temperature, it goes off. Then, turn the key to START. 3) START This is the position to start the engine. When your hand is released from the key after starting, it is automatically set in the position of RUN. 2.Local-remote change-over switch (in the control box) 1) REMOTE This switch should be set in this position when machine starts with an external device. 2) LOCAL This switch should be set in this position when machine starts with the starter switch. 3. Emergency stop button The stop button is a push button to stop the engine in case of an emergency. When the button is pressed, it must be unlocked by turning it anti-clockwise before the engine can be re-started. - 11 -
1-4-2 Engine indicators 4. Engine monitor (1) Engine indicator That indicates the numerical values of engine speed, engine oil pressure, run hours, battery charging voltage, or engine coolant temperature. Indicated Items Unit engine speed min -1 engine oil pressure battery charging voltage engine coolant temperature ºC 100kPa V 1 - Engine Speed Revolutions per minute is indicated. 1500 min -1 is indicated at 50Hz. 2 - Engine Oil Pressure 2.9 to 4.9 100 kpa should be indicated at normal engine operation. Higher value would be indicated in cold condition immediately after engine starts. Conduct a warning - up operation until it indicates normal value. 3 - Battery Charging Voltage That should indicate more than 26.0V at engine running. 4 - Engine Coolant Temperature That should indicate a temperature between 75 to 90 C at engine running. [ NOTE ]: If that would indicate higher temperature, disconnect all loads, decrease the speed for cool - down operation, and wait until the temperature comes down to normal value. - 12 -
E (2) Fuel Level Indicator That Indicates a fuel level in the fuel tank. All the lights are indicated green when the fuel is full. The green lights stop indicating one by one as the fuel level decrease, finally the red light will be indicated when it is only one green light is left. Replenish the tank when there becomes only one lamp turned on. The table below shows the relation between numbers of turn - on lamps and fuel level. Numbers of lamps DCA-220ESEI DCA-400ESEI turned-on Fuel level (L) Fuel level (L) 9 390 to full 410 to full 8 345 to 390 365 to 410 7 290 to 345 305 to 365 6 240 to 290 255 to 305 5 190 to 240 200 to 255 4 145 to 190 150 to 200 3 115 to 145 120 to 150 2 75 to 115 75 to 120 1 0 to 75 0 to 75 (3) Alarm and Memory at Abnormal Condition When any abnormal condition occurs in engine oil pressure, battery charging voltage, or engine coolant temperature, the indication will change as the following; 1 - The Indicator shows its defect with blinking numbers. 2 - When the abnormal condition is corrected, the on - and - off indication will stop. 3 - If engine would stop urgently and automatically or stop manually with the abnormal condition, the abnormal value will be memorized, and then indicated even after engine is started again. In this case, keep on pushing the button RESET for more than 5 seconds, and the abnormal indication will be reset to normal. - 13 -
(4) Warning Lamps This monitor indicates the following failures, if any one of them occurs. 1 High jacket water temperature (WATER TEMP) This lamp goes on when the water temperature rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. 2 Oil pressure failure (OIL PRESS) If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. 3 Air filter blinding (AIR FILTER) When the air element is blinded, this lamp goes on. Indicating that the element should be immediately cleaned or replaced. 4 Over speed of engine (OVER SPEED) This lamp goes on when the engine speed rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. (5) Hour Meter 1 When you turn the starter switch to RUN position, and push the selector button located on the right side of the Hour Meter, you can see the numbers mentioned below; ODD Total running hour TRIP A Running hours A on a certain period TRIP B Running hours B on a certain period 2 If you want to reset the Trip Meters, push the selector button for more than 1 second, after selecting each meters. - 14 -
(6) The hour meter has an internal battery The engine monitor incorporates both a rechargeable internal battery as well as a charging circuit. E While the generator is not in operation, the engine monitor will still indicate the hours operated via its internal battery. While the generator is in operation, the internal battery recharges. When the generator remains unused for a long period of time, the battery will continue to lose its charge. Once the charge is exhausted, the hour meter will not indicate hours, and the battery will need to be recharged. From a completely exhausted state, recharging the battery for 30 minutes will only result in a 30 minute charge to the battery. However, if charged for 3 hours, the hour meter will indicate hours for more than 10 days without another charge. Please refer to the table below to see the relationship between battery time charging versus length of indication by the hour meter. 5. Preheat lamp This machine has automatically preheating device. If turn the starter switch to RUN position, it will according to cooling water (coolant) temperature with the preheat lamp goes on. When the preheat lamp goes off, it indicates that preheating is completed. - 15 -
6. Electronic Governor Controller (in the control box) (1) Isochronous-Droop Change-over switch The generating set can change the governor control between Isochronous Governor Control and Droop Governor Control by Isochronous-Droop Change-over switch where is equippped with the control box. The original position at factory shall be set in Droop Governor Control. Operate the unit in condition of Droop Control in common. In case of starting with a heavy load, operate the unit in cindition of Droop Governor Control because it is better for starting efficiency than Isochronous Governor Control. Explanation for the control 1 Isochronous Governor Control ----- Frequency is constant regardless of load. When the generator is set in a frequency thet will be pointed in condition of NO-LOAD, the governor controls the frequency constantly regardless of load. 2 Droop Governor Control ----- Frequency will be alternative depending on load. Droop Governor Control means that frequency can be alternative depending on load. When the rated frequency will be reduced at about 2.0 Hz against NO-LOAD. Therefore, NO-LOAD frequency should be set at 52.0 to 52.5Hz. (2) Trouble diagnostic functions The engine controller with this unit diagnoses problems that arise with the engine control system and the engine itself. When diagnostic lamp is turned on, there are any failure in the engine control system. 1. When the generator is not in operation, turn the starter switch to the ON position. If operations are normal, the DIAGNOSTIC LAMP will turn off after a few second. If operation is abnormal, the DIAGNOSTIC LAMP will remain lit. - 16 -
2. If abnormal operation, push the DIAGNOSTIC BUTTON. Continue pushing the DIAGNOSTIC BUTTON, and the failure code will appear (Blinking display). E If operation is normal, the code 1 will repeatedly blink. If operation is abnormal, the failure code will blink three times. If there is more than 1 failure, it will repeat the codes in ascending order. So it would indicate the first failure three times, and then indicate the second failure three times, etc. After it has indicated all failure codes, it will repeat from the first failure code. While the engine is in operation, if a failure occurs, the DIAGNOSTIC LAMP will light, but cannot indicate the failure code. FAILURE DIAGNOSIS DISPLAY CODE CODE LOCATION OF FAULT CODE LOCATION OF FAULT 01 Normal Condition 118 151 Common Rail Pressures 14 Cam Sensor 158 159 Injector Drive Circuit 15 Crank Sensor 211 Fuel Temp. Sensor 16 Cam-Crank Pulse 225 Rail Pressure Limiter Open 19 Starter Cut Relay 227 Fuel Rail Pressure is Low (Fuel Leak) 22 Intake Air Temp. Sensor 245 Fuel Rail Pressure Sensor 23 Engine Coolant Temp. Sensor 247 Fuel Pressure Regulator Control Circuit 32 Boost Pressure Sensor 271~276 Injector Circuit 34 ECM Charge Circuit 294 Engine Oil Pressure Sensor 36 A/D Conversion 295 Boost Temp. Sensor 44 45 EGR 416 Main Relay Circuit 51~54 Engine Controller 542 Over Heat 55 5 Volt Circuit 543 Engine Over Run 66 Glow Relay 71 Barometric Pressure Sensor Check all of the connections. If connections are sound, Contact the Service department for repairs. - 17 -
1-4-3 Generator controls and indicators 7. Frequency meter This meter indicates the frequency of the outputted voltage. Make sure that it reads 50Hz when running. 8. Ammeter This meter indicates the current going to the connected load. It must not exceed the rated current. 9. Voltmeter The voltmeter indicates the outputted line voltage. 10. Three-phase circuit breaker The circuit breaker is a safety device interrupting the mains when an overload, a short circuit or a leakage occurs at the load side connected to the receptacles. It also serves as a main switch for supplying energy from the generator to the load connected to the output receptacles. Do not use this circuit breaker to turn on or off the load. When tripped, the breaker must be reset manually by switching it to OFF and then to ON after eliminating the cause of the trouble. 11. Earth leakage relay DANGER: Electric shock by leakage. Be sure to connect the machine to earth. If not connected to earth, the earth leakage relay would not work. Be sure to connect the load also to earth. This relay detects a leakage and trips the mains of the three-phase circuit breaker. The earth leakage relay sensitivity is 30mA. At this time, the red lamp lights indicating a leakage occurrence. Eliminate the cause of the leakage, press the reset button, turn the tripped circuit breaker manually to OFF and then to ON. 12. Ammeter change over switch The switch allows measuring the outgoing current between each of the phases and also switching the meter off. 13. Voltage regulator knob The output voltage is controlled by a regulator with rotating knob. Turning clockwise increases the voltage and vice versa. 1-5 Noise CAUTION: Injury of ears In room or environment where the sound pressure level reaches or exceeds 90dB(A), use ear protectors. The maximum sound pressure of the machine is the value specified in EN 31201. Model DCA-220. db(a) Model DCA-400. db(a) - 18 -
2. TRANSPORTATION, STORAGE AND INSTALLATION 2-1 Safety precautions for transportation, storage and installation E WARNING When lifting or transporting the machine, use only appropriate devices which comply with the local safety codes and regulations. When lifting the machine, use the hanger located at the roof center. Do not resort to rope winding because it is not strong enough. Before lifting, close and fix the doors, covers and other moving parts and clear away the machine interior and top. Do not slip under a lifted machine. The electrical connections shall comply with the local codes. Earth the machine properly. The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where the aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust sufficiently by a ventilating system. Never direct the engine exhaust towards passers-by. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise, fire or explosion might occur in the machine. (Example: Near volatilizing paint solvent.) Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not smoke while handling or refilling them. Do not get fire or heated objects near them. Do not spill or leave fuel, oil, anti-freeze solution or cleansing agent in or around the machine. If spilled, be sure to wipe off properly. If necessary, provide a spark arrestor to trap incendiary exhaust sparks. CAUTION Install the machine on a well ventilated, horizontal, flat, dry and solid floor. If the floor is not horizontal enough to keep the machine leveled, consult your sales distributor. When installing the machine on a trailer, fasten the trailer and fix the wheels by stoppers. Do not remove or unduly modify safety devices, guards, covers or insulating materials from the machine. When servicing batteries, always wear protecting clothing and glasses. The battery electrolyte is a diluted sulphuric acid which can cause severe burns. Get it away from eye, skin and clothing. When charging batteries, an explosive gas forms above the cells and escapes through the vents. Do not smoke near batteries just after having been charged. Never make or break live circuits or battery terminals, because a spark usually occurs. Before checking the machine, stop the engine and wait for at least 10 minutes so that it will cool down completely. If done while running or immediately after shutdown, you might get burnt or injured. - 19 -
2-2 Transportation When lifting or transporting the machine, use only appropriate devices which comply with the local safety codes and regulations. For dimensions and weight of the machine, refer to 7 Principal Data. See Fig 5 for the center of gravity. Fig. 5 Model L W H DCA-220ESEI 2120 725 950 DCA-400ESEI 2720 730 990 When lifting the machine, use the hanger located at the roof center. Never use the rope hanger because it is not strong enough to lift. Before lifting, close and fix the doors, covers, and other moving parts and clear away the machine interior and top. Do not slip under a lifted machine. Before transporting by truck or others, wind ropes on the machine to fasten it securely. Put covers so as to protect the machine from rain or moisture when transporting. 2-3 Storage 2-3-1 Storage method 1. Store the generator in a sufficiently ventilated, dry room which is free from frost, salt and dust. Storage environment: Atmospheric temperature -5 to 35 C (220ESEI : -5 to 40 C), humidity 85% or lower, altitude 1000m or lower. 2. Run the engine once a week until warm. - 20 -
3. If it is impossible to run the engine regularly, extra precautions must be taken. 1) Consult the instruction manual for the engine. E 2) Remove the battery. Store it in the same environment as for the machine. Keep the battery clean and coat its terminals lightly with petroleum jelly. Recharge the battery regularly. 3) If the electrolyte has dropped to the specified level, refill it. 4) Clean the generator. Oil or fuel spillage is not allowed. Protect all electrical components against penetration by moisture. 5) Place silica gel bags, VCI paper (volatile corrosion inhibitor) or another drying agent inside the generator and close the doors. 6) Close all openings on the bodywork by sticking sheets of VCI paper with adhesive tape. 7) Enclose the generator, except the bottom, with a plastic bag. 2-3-2 Preparing for operation Before operating again the generator kept unused for a long time, remove the plastic bag, VCI paper from the openings and silica gel from inside and check the generator thoroughly. Further maintain the following items. 1. Consult the instruction manual for the engine. 2. Measure the insulation resistance of the generator with a 500-V insulation resistance tester. The resistance must exceed 1 MΩ. In case of measuringwith an insulation resistance tester over 500VDC current, disconnect all connectors from the AVR located in the control box before measuring. 3. Replace the fuel filter cartridge and fill the fuel tank. Vent the fuel system. 4. Reinstall and connect the battery. If necessary, recharge it. 5. Check the fan belt condition and tension; adjust if required. 6. Check and, if required, refill cooling water and oil. 7. Submit the generator to a test run. - 21 -
2-4 Installation 2-4-1 Installation 1. Install the generator on a well ventilated, horizontal, even and solid floor. If the floor is not horizontal enough to keep the machine leveled, consult your sales distributor. When installing the machine on a trailer, fasten the trailer and fix the wheels by stoppers. Avoid a site exposed to rain or high temperature. The operating ambient conditions are atmospheric temperature of -5 to 35 C (220ESEI : -5 to 40 C), humidity of 85% or lower and altitude of 1000m or ower. If the machine do not conform with the above conditions, consult your sales distributor. 2. Avoid a dusty site. If it is inevitable, provide protective devices. 3. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise fire or explosion might occur in the machine. (Example: Near volatilizing paint solvent.) 4. Leave space for operation, inspection and maintenance; at least 1200 mm each on machine front and rear and sides. See Fig. 6 Fig. 6 [ NOTE ]: If the machine is operated in a smaller space than that shown above, the room temperature will rise. Please reduce the generator output in such condition. Therefore proper power reduction is necessary. If the space required above the machine is not uniform when it is operated indoors, make a decision so that: The radiator can be refilled with cooling water. The exhaust pipe can be introduced. The exhaust can smoothly be discharged. - 22 -
5. Do not direct the exhaust towards passers-by or residences, etc. 6. If the generator is operated indoors; E Install an exhaust pipe of sufficient diameter to let the engine exhaust gas out directly. Check for sufficient ventilation and position the ventilator so that the exhaust from the machine will not be re-circulated in the room even if the ventilation is proper. 7. Check that the inner earthing system is in compliance with the local regulations. 8. Earthing the machine If the machine is earthed in a way different from below, follow the local rule. The machine is TN system which must conform to IEC 364-3 and must directly be earthed at one neutral point. 1 Be sure to connect to earth the earthing bar connected to the PE earthing terminal. 2 Avoid earthing at the following places 1. Near underground utilities such as gas pipe, city water pipe, electric wires, underground cables. 2. Within 2m from lightening arrester earthing place. 3. Do not use the high voltage circuit earth commonly earthing the machine. 3 Precautions in earthing 1. Drive the earthing lugs as near the machine as possible in shady and humid soil so that its top end will sufficiently be buried inside. 2. Be sure to connect the lead-wise securely if the hanger is buried in a place of heavy traffic. 9. Also connect the load bodyworks to ground. - 23 -
Model DCA-220ESEI Model DCA-400ESEI Fig. 7 1. Oil level gauge 6. Alternator 2. Oil refilling port cap 7. Fuel pre filter 3. Oil filter 8. Fuel filter 4. Reserve tank cooling water 9. Air cleaner 5. Fan belt 10. PCV filter - 24 -
2-4-2 Checking after installation (1) Check engine oil (Read the instruction manual for the engine furnished separately.) E 1 Check the level of engine oil by the dipstick. Make sure the oil level is always between H and L. 2 When it is below the low limit, supply oil immediately. 3 At the same time, check condition of oil by the dipstick. [ NOTE ]: Oil is consumed gradually during operation. When the machine is to be used continuously for a long time, be careful with lack of oil. (2) Check engine cooling water (Read the instruction manual for the engine furnished separately.) 1 Check (to see) that cooling water in the reserve tank is within the range of FULL-LOW. 2 When it is below the low limit, supply (additional) water immediately. 3 Normally, only the water level of the reserve tank needs to be checked. But, the radiator cap should be opened once a week to check that water is full in the radiator. [ NOTE ]: When closing the radiator cap after water level is checked or water is supplied, turn the cap fully clockwise so that it can be firmly tightened. Otherwise, cooling water is evaporated which results in serious damage to the engine. (3) Check fan belt (Read the instruction manual for the engine furnished separately.) 1 Check the belt for tension and elongation. Also, check it for damage. Replace if necessary. 2 For adjustment or replacement of the belt, refer to the instruction manual for the engine. Press (about 6kg) the position shown by arrow mark (middle of belt) with your thumb. The bend should be within the range of 10 mm. Parts number of fan belt: Model name Parts number Parts number of manufacture DCA-220ESEI Y06020 15251 113671-4730 DCA-400ESEI Y06020 15252 113671-4740 (4) Check fuel level 1 Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation. 2 Loosen the drain plug of the fuel tank from time to time, and remove sediment s and water at the bottom of the tank. - 25 -
CAUTION Battery The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. In the worst case, it will put out your eyes. (5) Check battery acid level Remove the battery acid plug(cap) and check the liquid level (10-12 mm above the electrodes). Supply distilled water if necessary. (6) Check for leak of water and oil Check the machine for the trace of leak of oil or water. If a leak is found, check the location of leak and stop it. When the leak cannot be stopped, contact our service factory. (7) Check for loose parts Check for loose bolts and nuts. Loose parts should be tightened firmly. Particularly, make check on (the fitting of air cleaner, muffler, turbo-charger, etc.), disconnection of electric wiring, short-circuit and loose terminals. (8) Removal of foreign objects in machine Check that tools and cleaning cloth are not left in the machine. Remove if necessary. Check the surroundings of the muffler and engine for presence of dust and flammable objects. Remove if necessary. Check that the cooling air inlet and the cooling air outlet of the machine are not clogged with dust or other objects. Remove if necessary. - 26 -
3. OPERATION 3-1 Safety precautions for operation E DANGER When the machine is running, never touch output terminals, internal wiring or other electrical parts. Do not use the machine in a humid place. An excessive humidity is very dangerous. Never touch the machine if the machine or your body is wet. Never fail to perform a test running for the earth leakage relay prior to operation. The electrical connections shall comply with the local regulations. Use cables which are not damaged. Make sure that all electrical connections are securely fastened. Damaged cables or loose connections might cause electric shocks. WARNING The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where the aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust by a ventilation facility. Do not direct the engine exhaust towards passers-by, residences, etc. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise, fire or explosion might occur in the machine. (Example: Near volatilizing paint solvent.) Do not refill fuel or oil while the machine is running but after stopping the engine. Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not smoke while handling or refilling them. Do not get fire or heated object near them. Do not spill or leave fuel, oil, anti-freeze solution or cleansing agent in or around the machine. Never remove the cover of the output terminals during operation. Before connecting or disconnecting the cables, switch off the load and machine circuit breakers, stop the machine and make sure that the machine cannot be started inadvertently. - 27 -
CAUTION Avoid overloading the generator. The generator is provided with circuit breakers for overload protection. When a circuit breaker has tripped, reduce the concerned load before re-starting. Do not connect the output voltage from the machine to facilities wired to the commercial power supply. Before connecting a load, turn off a corresponding circuit breaker and make sure that the frequency, voltage and power factor of the load to connect match the generator ratings. Before checking the machine, stop the engine and wait for at least 10 minutes so that it will cool down completely. If done while running or immediately after shutdown, you might get burnt or injured. Do not operate the machine beyond the range given in the main specification table. In room or environment where the sound pressure level reaches or exceeds 90 db (A), use ear protectors. During the operation, keep all doors closed. Periodically check that: 1. All guards are in place and securely fastened. 2. All hoses and/or pipes inside the machine are in good condition, not bent and not rubbing. 3. There are no leaks of fuel, oil, cooling water, etc. 4. All fasteners are tight. 5. All electrical leads are secure and in good order. 6. The electrical cables are not damaged. [ NOTES ]: Do not remove any of, or tamper with, the sound-damping material. Whenever an abnormal condition arises, e.g., excessive vibration, noise, odour, etc., switch the circuit breakers to OFF and stop the engine. Correct the faulty condition before re-starting. - 28 -
3-2 Connecting the load 3-2-1 Precautions in connecting the load E The switchgear, switching equipment, load and generator in the plant must be connected in compliance with local codes of low voltage power installation (1000 or less). Before starting or before connecting a new load, make sure that the generator is earthed. Use the earthing rod or, if effective, use an existing earthing installation. Any protective devices against electric shock and leakage would be useless if earthing is poor. Avoid overloading the generator. The generator is provided with circuit breakers for overload protection when a breaker has tripped, reduce the concerned load before restarting. Never connect the generator output voltage to an installation which is also connected to a commercial power supply. Before connecting a load, turn off the corresponding circuit breaker, and check whether frequency, voltage and power factor comply with the ratings of the generator. Distribution board If the outlets provided on the machine are insufficient, provide an auxiliary switchgear and connect it with the output terminals. The distribution board must comply with the local rule of power installation. Be sure to provide a load ON/OFF switch between the power outlets and load. Do not use the generator circuit breaker to turn on/off the load. Before connecting the load, stop the engine and turn off the generator circuit breaker. The load connecting cable must not get in contact with other output terminals on the terminal board. 3-2-2 Non-linear and sensitive loads Non-linear loads draw currents with high contents in harmonics causing distortion in the wave form of the voltage generated by the synchronous generator. In general, non-linear type loads generate a high frequency current which adversely affects the performance of inverters used to feed power voltage to variable speed motors or loads such as thyristor/rectifier controlled UPS. Loads most sensitive to voltage distortion include incandescent lamps, discharge lamps, computers, X-ray equipment, audio amplifiers and elevators. Consult your sales distributors for measures against the adverse influence of non-linear and sensitive loads. - 29 -
3-2-3 Selection of cables Use cables having sufficient size in consideration of the allowable current of the cables and the distance between the machine and the load. If the load current exceeds the allowable current of cables, the cable may be damaged by overheat. Also, if the cables are too small in size for the length, the input voltage of the load drops which lowers the working efficiency or causes failure in operation. Select the length and size of cable so that the voltage drop e obtained by the following equation is within 5% of the rated voltage. * Equation to obtain 3-phase, 3-wire system voltage drop e from the length and size of cable and operating current is as follows. e = Voltage drop (V) L = Length of one wire (m) I = Generator rated current (A) S = Cable thickness (mm 2 ) - 30 -
3-2-4 Connecting the load 1. Check whether frequency, voltage and current conform with the ratings of the generator. E 2. Install for the load cable, without excessive length, and lay it out in a safe way without forming coils. 3. In case of single-phase load, engage the specified plugs with the specified receptacles (Fig. 8). 220ESEI 400ESEI Fig. 8 1. Cable clamp 2. Rubber cover 3. PE earthing terminal 1. Output terminal L1 2. Output terminal L2 3. Output terminal L3 4. Output terminal N 5. External protection conduct terminal PE Fig. 9-31 -
5. When connecting output terminals (See Fig. 9.) Remove the protection cover of output terminals. Loosen the cable clamp and push the wire ends of the load cable through the clamp and rubber cover. Connect the wires to the proper terminals: L1/L2/L3/PE, and if required N, for 3-phase load N/L1, N/L2, N/L3 and PE for single-phase load Tighten the bolts securely. Reinstall the protecting cover in front of the output terminal board. Tighten the clamp to fasten the cable. 3-3 Before starting The generators are factory-adjusted to operate at 50 Hz, i.e. 1500 min -1. 3-3-1 Checkup before start-up 1. Checking the oil level Check the engine oil level or contamination by the dipstick. The oil level must be near to, but not exceed, the high mark on the dipstick. If required, refill or change the oil. If necessary, pour oil up to the specified level through the oil refilling port provided on the engine. For oil change, loosen the oil drain plug from the generator base to drain and, thereafter, pour oil the same as refilling. Dispose of the discharged oil in compliance with the local regulations. After supplying oil, run for several minutes, then stop the engine and make sure that the oil level is between the high and low marks. For the oil volume, see the lubricant volume in the specification table. 2. Checking the cooling water in engine radiator Check that the water level is near the Full mark on the auxiliary tank. Refill if short. Use soft water as engine cooling water. Use anti-freeze solution where the atmospheric temperature is low. Mixing volume of anti-freeze solution = total cooling water volume mixing anti-freeze solution concentration. For the total cooling water volume, see the engine specification table. For anti-freeze solution concentration at the temperature, see Fuel coolant and lubricants. For making up water, remove the radiator cap. Thereafter, securely install the cap so as to be airtight. - 32 -
3. Checking the fan belt tension E Check the fan belt tension and elongation. By a thumb, depress (approx. 6kg) the middle point of the belt. The deflection must be 10-15 mm. At the same time, check whether the belt is scratched or not. If abnormal, adjust or replace it. For belt checkup, adjustment and replacement. 4. Checking the fuel Check the fuel level. Refill if required. If the fuel remainder is small, dew might be formed in the tank and mix with the fuel. To avoid such inconvenience, it is recommended to refill the tank fully after the day s work. Loosen the drain plug from the fuel tank to drain water and sediment from the tank. Dispose of the sediments, etc. in compliance with the local codes. 5. Checking the battery Check whether the electrolyte level is within the specified range or not. If short, add distilled water. If plates are exposed to air for a long time, the battery life would shorten. Keep them dipped. Do not pour battery electrolyte beyond the UPPER LEVEL. After refilling, securely tighten the caps. Give attention to the connection of battery plus (+) and minus (-) terminals. Reverse wiring of the terminals will cause damage to generator instruments. 6. Checking the wiring Check whether the wiring is securely tightened or rubbed. If abnormal, repair or replace. 7. Checking the piping Check whether the piping is securely tightened or leaky. Make sure that the hoses are not worn. If abnormal, repair or replace. 8. Checking the bolts and nuts Check whether bolts and nuts are securely tightened or not especially for the air cleaner, muffler mounting section. If loose, retighten them. - 33 -
3-3-2 Instruction for Fuel Source Changeover Device (Three-Way valve) (1) Setting Procedure for Separate Tank 1 When the machine is shipped from factory, the three way valve is sets as shown in the Fig.10. In the case that fuel source is the mounted fuel tank, run the machine without changing the setting of the piping and valve lever. 2 Where fuel source is a separate tank placed outside the machine, disconnect the tank connection plug and change the connection as shown in the Fig.11. And also switch the lever of three-way valve to the direction of the arrow mark as shown in the Fig.12. (2) Caution on Setting 1 For the piping, use oil-resistant hose of 8 to 10 mm internal diameter. Under Cold environment, use the hose of lager diameter. 2 Install the separate fuel tank as near the machine as possible. 3 Reconnect the piping for the separate tank while the lever of three-way valve is unswitched as shown in the Fig.10. Switch the lever after completing the reconnection work. 4 Set the suction end in the separate tank at the position of 15 to 20 mm upper than the bottom level (as shown in Section-A of the Fig.11), so that water or sediment may not come into the suction. 5 While feeding the fuel into the separate tank, do not allow water or dust to come in. Fig. 10 Fig. 11 Fig. 12 3-4 Starting 1. Insert the key in the starter switch. Turn the key to RUN and the PREHEAT LAMP lights up. When the lamp goes off, turn the key to START. The switch automatically returns to RUN. If the key does not automatically return to RUN, manually return it. Otherwise, the starter motor might be damaged. The duration of preheating differs according to the temperature of cooling water. And if the temperature of cooling water is high enough, the preheat lamp does not light because no preheating is required. Do not engage the starter for more than 10 seconds at a time; if the engine does not fire, wait 2 minutes before restarting. Consult your sales distributor if starting is in extremely cold conditions. If the engine would not start after several tries, check whether the fuel level is too low, air is not bled sufficiently or the battery is discharged. - 34 -
2. Make sure that the engine warning lamps is extinguished. If alight, stop the engine, check the item for which it is alight and eliminate the cause. Check the engine indicator for normal readings. E 3. Check whether the frequency meter read as shown below or not. 50-Hz operation Frequency 52.0~52.5 Hz Check the voltmeter indication and, when the voltage is deviated from the rated voltage, please contact your nearest Distributor. 4. Check the voltmeter indication and, if required, adjust with the voltage regulator knob. Turning clockwise increases the voltage and vice versa. 5. When three-phase voltage is supplied, switch the three-phase circuit breaker to ON. With single-phase voltage, switch three-phase and single-phase circuit breakers to ON. 6. Test the earth leakage relay for operation. Testing the operation. 1) Press the test button of the earth leakage relay. 2) Normally, the earth leakage relay red lamp lights up and the circuit breaker operates. 3) Press the reset button of the earth leakage relay. Switch the circuit breakers to OFF and then to ON. A tripped earth leakage relay is kept tripped until the reset button is pressed or the generator is suspended. 7. Switch on the load and check the frequency meter and voltmeter once more. Adjust voltage if necessary. Frequency (3-phase) Voltage 50-Hz operation 50 Hz 380~415V 8. After starting, close the rear frame door. During the operation, keep all the doors closed. - 35 -
3-5 During operation 1. Periodically check that Indications of the engine monitor, indicator lamps and meters are normal. Oil, fuel and cooling water do not spill. The engine exhaust color is normal. There are no unusual sound and vibration. A light load is not applied for a long time. Otherwise, the engine output might drop. Each single-phase load is connected in balance whenever it is used. The engine oil level checked weekly is normal. Refill if necessary. [ NOTE ]: If the circuit breakers are tripped during operation, switch off the load and stop the engine. Check and, if necessary, decrease the load. 3-6 Stopping 3-6-1 Stopping method 1. Switch the load circuit breakers to OFF. 2. Switch the generator circuit breaker to OFF. 3. Let the engine run for about 5 minutes to cool down. 4. Stop the engine by turning the key to STOP. 5. If the machine is not used any longer, withdraw and keep the key. 6. Close and lock the rear frame door so as not to be tampered with by third person. 3-6-2 Emergency stop To stop the engine in an emergency, press the emergency stop button. 3-6-3 Protection device Protection devices and emergency stop devices are provided for protection of the machine against trouble during operation. When the warning lamp lights, stop the engine immediately. Check and remove the cause of trouble. - 36 -
Table of protection device warning action turn OFF the circuit breaker stop the engine indicate by warning lamp function E oil pressure failure (OIL PRESS.) high jacket water temperature (WATER TEMP.) Battery charging failure overcurrent of generator fuel level failure (FUEL LEVEL) air filter blinding (AIR FILTER) set point: 130kPa stop set point: 100kPa set point: 97 C stop set point: 105 C set point: 26.0V When overcurrent flows, the device acts. When fuel supply is necessary because of fuel shortage, the device acts. When replace or cleaning of air filter is necessary because of blinding of filter, the device acts. earth leakage When electric leakage, the device acts. Current sensitivity: 30mA over speed of engine (OVER SPEED) stop set point: 1725 min -1 Abnormal value and unit will be indicated lighting on and off. Engine stop switch 1 The engine will not start when the side door is open. 2 The engine will stop if the side door is opened during operation. - 37 -
4. REMOTE CONTROL 4-1 Outline of the operation This machine is equipped with remote function so as to start and stop by the external signals. 4-2 Indications and operation device This machine is equipped with LOCAL-REMOTE CHANGE-OVER SWITCH and TERMINAL BLOCK for the connection to external devices mentioned below. (1) Remote start-stop signal This machine can start and stop by the signals of ON and OFF come from external devices. (2) Generator fault signal Indication lamp ( 12V or 24V ) less than 3W can be connected for the abnormality indication in case of emergency engine shut down. (3) Battery charger Automatic floating battery charger can be connected for long term standby condition. 4-3 Local operation ( operation by the starter switch ) Turn the LOCAL-REMOTE CHANGE-OVER SWITCH to LOCAL, and start the engine with the starter switch on this machine. Refer to P.33 3-4 Starting of instruction manual for the details. 4-4 Remote operation Turn the LOCAL-REMOTE CHANGE-OVER SWITCH to REMOTE. This machine can start and stop by ON-OFF signals from external devices. 4-4-1 Setting of operation switches Before remote operation, start this machine at local position to set the voltage and the frequency. After then, set each operation switches as mentioned below. Also, make sure these setting positions after making maintenance and inspection without fail. ENGINE GENERATOR (1) Set the starter switch to RUN position. (2) Set the voltage regulator to the rated voltage position. (3) Turn the circuit breaker to ON position. (4) Turn the REMOTE-LOCAL CHANGE-OVER SWITCH to REMOTE position. Note: External signals must be OFF during the setting of these switches on this engine generator. 4-4-2 Starting (1) Start-signal ( ON ) is sent from external devices. (2) After preheating period ( T1 sec. ), the engine will start. (3) If the engine cannot start with the first cranking ( for T2 sec. ) it will cease the engine cranking ( for T2 sec. ). Then it will try the second cranking. This operation will be repeated 3 times. If the engine cannot start after 3 times of cranking, it will stop the cranking. Then it will send generator fault signal to external devices. Check and remove the cause of trouble. - 38 -
4-4-3 Stopping (1) Stop-signal ( OFF ) is sent from external devices. (2) The engine will stop, and it will confirm stop-condition for T4 sec. E If the engine cannot stop by the stop-signal, or if you need to stop the engine during remote operation, turn the LOCAL-REMOTE CHANGE-OVER SWITCH to LOCAL position, and turn the starter switch to STOP position. Note: Refer the attached time chart for the detail. 4-5 Cautions of operation (1) In case of remote operation, Keep people away from this machine because it may start suddenly without prior notice. (2) While this machine is running, don t operate the local-remote changeover switch except an emergency case. 4-6 Protective devices 4-6-1 Protective devices for remote operation The following protective devices are provided against abnormalities during the operation. Starting failure : In case that engine cannot start within the setting time. Low oil pressure : In case that the oil pressure becomes lower than the setting value. High water temp : In case that the cooling water temp. becomes higher than the setting value. Emergency shutdown : In case of emergency engine shutdown by the emergency stop button on this machine. Overcurrent : In case that the circuit breaker trips. Overspeed : In case that the engine speed becomes higher than the setting value. Earth leakage : In case that the eletctric leakage the device act. Mark : Action Mark : Action after engine shutdown ASSORTMENT Generator Fault Output Engine Shutdown Circuit Breaker trip Starting failure Low oil pressure High water temperature Emergency shutdown Overcurrent Earth leakage Overspeed If these protective devices have acted, check these causes, and remedy them. - 39 -
(1) In case of shutdown due to action of engine protective devices, turn the starter switch OFF position to reset these protective devices. When making inspection and remedy on defected part, close the fuel cock, and disconnected the battery cable on negative side of this machine for safety sake. (2) The engine cannot start immediately after the engine stop due to the engine stop confirmation time ( for T4 sec. ). The engine can start after T4 sec. 4-7 Fault diagnosis Refer the engine instruction manual for this engine. Check disconnection and bat connection of wires without fail. 4-7-1 Starting failure ( causes ) (1) Engine cannot start even after receiving start-signal at remote operation. Remote unit defective (N3) --------------------------------------Replacement (2) The starter motor cannot work, poor cranking. Or the starter motor stopped just after the starting of engine cranking, etc. Battery defective, short capacity, low voltage-------------charging, or replacement Starter motor defective------------------------------------------remedy, or replacement Remote unit defective (N3) ------------------------------------Replacement Relay defective (K11) -------------------------------------------Replacement (3) Others No fuel in fuel tank ----------------------------------------------Fuel supply Bad fuel or fuel system defective ---------------------------Remedy, or replacement Engine governor defective ------------------------------------Remedy, or replacement Air inlet and outlet system defective -----------------------Remedy, or replacement Bad engine oil or lubrication system defective ----------Remedy, or replacement Engine electrical parts defective ----------------------------Remedy, or replacement Remote unit defective (N3) -----------------------------------Replacement 4-7-2 Abnormality during operation ( causes ) (1) Protective devices does not operate or operates faultily, etc. Engine defective-------------------------------------------------check or remedy Battery defective, short capacity, or low voltage--------charging, or replacement Detector defective ( oil, water, temp.,switch )-----------Replacement Remote unit defective (N3) -----------------------------------Replacement (2) Engine cannot stop Engine electrical parts defective ----------------------------Replacement Relay defective --------------------------------------------------Replacement Remote unit defective (N3) -----------------------------------Replacement Note Please refer to the outline drawing and the engine wiring diagram in the delivery specification of the separate volume. - 40 -
4-8 Attached time chart E T1 : Preheating time T2 : Cranking time T4 : Stopping time 3S 5S 15S - 41 -
5. FUEL, COOLANT AND LUBRICANTS Engine oil selection: For engine oil, use API grade : CD, CE, CF, CF-4, CH-4, CI-4, CI-4 plus or ACEA grade : A3/B3, A3/B4, A5/B5, E2, E3, E4, E5, E7 or JASO grade : DH-1. The brands/types of oil described ISUZU s instruction manual can be used regardless of specified API or ACEA grade above. Oil viscosity: Engine oil viscosity largely affect engine startability, performance, oil consumption, speed of wearing and occurrence of seizure, etc. Using lubricants whose viscosity selected according to the atmospheric temperature is important. Fuel selection: The following specific advantages are required for the diesel fuel. 1) Must be free from minute dust particles. 2) Must have adequate viscosity. 3) Must have high cetane value. 4) Must have high fluidity at low temperature. 5) Must have low sulfur content. 6) Must have little residual carbon. Applicable Standard JIS (JAPANESE INDUSTRIAL STANDARD) DIN (DEUTSCHE INDUSTRIE NORMEN SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE-J-313C BS (BRITISH STANDARD) Based on BS/2869-1970 Recommendation NO. 2 DIN 51601 NO. 2-D Class A-1 In fuel other than the specified one is used, engine function will be lowered. - 42 -
This machine is designed to use either Number 1-D or Number 2-D diesel fuel. However, for better fuel economy, use Number 2-D diesel fuel whenever possible. At temperatures less than -7, (20 o F), Number 2-D fuel may pose operating problems ( see Cold Weather Operation which follows). At colder temperatures, use Number 1-D fuel (if available) or use a winterized Number 2-D (a blend of Number 1-D and Number 2-D). This blended fuel is usually called Number 2-D also, but can be used in colder temperatures than Number 2-D fuel which has not been winterized. Check with the service station operator to be sure you get the properly blended fuel. Note that diesel fuel may foam during a fill-up. This can cause the automatic pump nozzle to shut off even though your tank is not full. E Cooling water : Always refer to the chart to determine the correct cooling water to antifreeze solution mixing ratio. - 43 -
6. PERIODIC CHECKUP AND MAINTENANCE 6-1 Safety precautions for periodic checkup and maintenance WARNING Before checking or maintaining the machine, stop the engine, wait for it to cool down and remove all loads from the machine. Make sure that the machine would not accidentally start. Otherwise, you might be dead or injured by electric shock, burn, catching of hand or clothing, etc. Do not carry out work which will produce heat near fuel, oil, anti-freeze solution or combustible substances. If such is absolutely required (steam washing, for example), keep away combustible substances. Keep a fire-extinguisher in the vicinity. Take safety precautions against fire. Fuel, oil and anti-freeze solution are combustible. Handle them with care. When handling them, do not smoke or do not get naked flame near them. Keep a fire-extinguisher in the vicinity. CAUTION Do not use combustible solvents or carbon tetrachloride for cleaning the machine or parts. Take safety precautions against toxic fumes of cleansing agent. When checking or maintaining, protect the air filter, electrical parts, meters, etc. from moisture or humidity. Pay attention so that moisture humidity will not penetrate any part. When checking or maintaining, cover the replacing parts and generator openings with clean cloth, paper, tape, etc. so that the parts and generator interior will not he contaminated or moistened. Particularly, the air cleaner, electrical parts and terminals shall not be splashed with water. Before removing the radiator cap, stop the engine and wait for at least 10 minutes for it to cool down. If done while, or immediately after the end of, running, you might get burnt or injured. When servicing batteries, always wear protection clothing and glasses. The electrolyte is a sulphuric acid which can cause severe burns. Get it away from eye, skin and clothing. When charging batteries, an explosive gas forms above the cells and escapes through the vents. Do not smoke near batteries being, or just after having been charged. Never make or break live circuits or battery terminals, because a spark usually occurs. Do not leave tools, parts, rags etc. in or on the machine. Do not leave rags, paper, etc. near the air intake port of the machine. All sound-damping materials of the machine shall be normal. If damaged, repair them to prevent the sound pressure level from rising. Do not remove or tamper with them. [ NOTES ]: Do not reuse gaskets, O-rings, packings, etc. removed for checkup or maintenance. Do not remove, tamper with or remodel covers, protective devices, etc. without our permission. Use only genuine parts for replacement, repair, supply, etc. - 44 -
Use only the correct tools for maintenance and repair work. After checkup or maintenance, carry out a test run to make sure that the generator, controls, circuit breakers, etc. operate properly. E 6-2 Periodic checkup The periodic checkup and maintenance are outlined. Read the relevant section beforehand. Only personnel so qualified are allowed to carry out checkup and maintenance. Routine checkup and maintenance items for the engine are described here. For further details, see the instruction manual for the engine. The Long Interval checks must include the Shorter Interval checks. For checkup and maintenance, wear protecting clothing, glasses, etc. 6-2-1 Maintenance schedule 250 hours: Checking/every 250 hours Cleaning of air cleaner element Measurement of generator insulation resistance (once a month) Checking on battery specific gravity 500 hours: Checking/every 500 hours Replacement of engine oil Replacement of engine oil filter element (220ESEI : oil filter, 400ESEI : main filter and partial filter) Replacement of PCV filter element Replacement of fuel filter element (pre filter and main filter) Cleaning of radiator and intercooler Cleaning feed pump strainer Inspection of injection nozzle Checking for terminal and connection of the circuit Checking/every 250 hours is also required. 1000 hours: Checking/every 1000 hours Cleaning inside fuel tank Replacement of air cleaner element Adjustment of fuel injection timing Checking on rubber suspension Checking on nylon and rubber hose Checking on lining Checking/every 250 and 500 hours are also required. On the engine system, main checking items only are shown in this manual. For details, refer to the instruction manual for the engine furnished separately. - 45 -
6-2-2 Checking/every 250 hours (1) Cleaning of air cleaner element This element should be cleaned, regardless of operating time, when the warning lamp of Air filter blinding goes on. - Dry dust clings on element - Remove the air cleaner element and clean the element with dry and clean compressed air. While it is being cleaned, check the element for any damage. Replace if necessary. Before installing the air cleaner, wipe off dirt on the element cover. When insert the element, insert the element completely pressing equal edge of element. (2) Measurement of insulation resistance A 500-V insulation resistance tester is required to measure the insulation resistance of the generator. In case of measuring with an insulation resistance tester over 500VDC current, disconnect all connectors from the AVR located in the control box before measuring. Remove the load cables and earthing cable for the leakage relay. Turn on the 3-phase circuit breaker, connect the insulation resistance tester between bodywork earthing terminal and output terminal for measurement. The result must be more than 1 MΩ. Otherwise, there is a risk of electric shock or fire. Consult the distributor. (3) Check on battery specific gravity Measure the battery gravity if there is a suspicion that battery leakage has occurred especially where there have been instances where the machine would not start. The relationship between Battery Gravity and Battery Charging at 20. battery Gravity battery Charging Over 1.28 Over charged (need adjustment) 1.25 1.28 Optimal charging 1.24 1.25 Average Below 1.24 Low charged (need adjustment) In determining the specific gravity at a temperature other than 20, use the following formula: S 20 = St + 0,0007 (t-20) where S 20 : is the calculated specific gravity at 20. St : is the measured specific gravity t : is the battery solution temperature reading. - 46 -
6-2-3 Checking/every 500 hours Checking/every 250 hours is also required. E (1) Replacement of engine oil 1 Remove the engine oil drain plug and discharge oil completely. It can be discharged easily when the engine is warm. 2 After engine oil is discharged, tighten the plug firmly. 3 Charge new engine oil from the oil filler until it reaches the notched line of the "H" on the dipstick. 4 After engine oil is supplied, run the engine for a few minutes. Check that oil is supplied to the level between H and L. (2) Replacement of engine oil filter element (220ESEI) 1 Set a wrench at the hexagonal section of the second stage above the cartridge, and remove the main oil filter. 2 There may remain the used engine oil in the cartridge, and care should be taken not to spill it when removing the filter. Discard the used filter. 3 Apply lightly engine oil to the O-ring. 4 Turn in new cartridge until its sealed face comes in contact with the O-ring. 5 Use a filter wrench to further turn in the cartridge by one full turn. DCA-220E 220ESEI Parts number of oil filter element: Model name Parts number manufacture Parts number of manufacture DCA-220ESEI Y06020 41221 ISUZU 113240-2322 (3) Replacement of main oil filter element (400ESEI) 1 Loosen the oil drain plug on the filter and drain oil in the filter. Then tighten the drain plug to the specified torque after draining oil. Torque : 44 Nm (4.5 kgm) 2 Remove the center bolt and replace the element. Discard the used element. 3 Apply engine oil to the gasket and install it in the groove. Install the new element in the case and tighten the center bolt to the specified torque. 4 Install the oil filter with the drain plug of filter case faced rear. Torque : 44 Nm (4.5 kgm) DCA-40 400ESEI Parts number of main oil filter element: Model name Parts number manufacture Parts number of manufacture DCA-400ESEI Y06020 41219 ISUZU 113240-2330 - 47 -
(4) Replacement of partial oil filter element (400ESEI) 1 Loosen the oil drain plug on the filter and drain oil in the filter. Then tighten the drain plug to the specified torque after draining oil. Torque : 44 Nm (4.5 kgm) 2 Remove the center bolt and replace the element. Discard the used element. 3 Clean the oil passage of the center bolt. 4 Apply engine oil to the gasket and install it in the groove. Install the new element in the case and tighten the center bolt to the specified torque. 5 Install the oil filter with the drain plug of filter case faced rear. Torque : 49 Nm (5.0 kgm) Drain plug DCA-400 400ESEI Parts number of partial oil filter element: Model name Parts number manufacture Parts number of manufacture DCA-400ESEI Y06020 41220 ISUZU 113240-2410 (5) Replacement of PCV filter element 1 Wipe clean around the PCV filter cap taking care so that no foreign particles entry. Remove the PCV filter cap. 2 Remove the PCV filter element. 3 Install the new PCV filter element. 4 Install the PCV filter cap. Parts number of PCV filter element : Model name Parts number Manufacture Parts number of manufacture DCA-220,400ESEI Y06020 44210 ISUZU 898030-5320 - 48 -
(6) Replacement of fuel filter element (pre filter and main filter) 1 Loosen the drain plug and air bleeding plug, and drain the fuel in the filter. 2 Use a specified filter wrench to remove the cartridge. 3 Replace the O-rings of the cartridge and drain plug with new ones. Insert a new element into cartridge and apply fuel to the O-ring. Turn the new fuel filter until the filter O-ring comes in contact with its sealed face. Use a specified filter wrench to turn in the fuel filter. Torque (Cartridge) : 29.4 Nm (3 kgm) Torque (Drain plug) : 1.5 to 2.5 Nm (0.15 to 0.25 kgm) E Parts number of fuel pre filter cartridge: Model name Parts number Manufacture Parts number of manufacture DCA-220,400ESEI Y06020 42516A ISUZU 898074-2880 Parts number of fuel main filter cartridge : Model name Parts number Manufacture Parts number of manufacture DCA-220,400ESEI Y06020 42515 ISUZU 898008-8401 (7) Cleaning of radiator and intercooler When the fin or tube is blinded, it should be cleaned with steam or high pressure water. [ NOTE ]: When a high pressure washer is used, spray water from a place about 1.5m away to prevent damage to the fin or tube. (8) Cleaning feed pump strainer 1 The strainer is incorporated in the feed pump inlet side joint bolt. Clean the strainer with the compressed air and rinse it in the fuel oil. 2 Do not reuse removed high-pressure inlet pipe. Reused metal contact seal may be misaligned. This causes fuel leakage. DCA-220 220ESEI DCA-400 400ESEI (9) Checking for terminal and connection of the circuit. Check for main and sub circuit, whether there are no abnormality such as loosening, corrosion and burning, etc. - 49 -
6-2-4 Checking/every 1000 hours Checking/every 250 and 500 hours is also required. (1) Cleaning inside fuel tank Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. (2) Replacement of air cleaner element The element should be replaced referring to Cleaning of air cleaner element. Parts number of air cleaner element: Model name Parts number Manufacture Parts number of manufacture DCA-220ESEI Y06020 46618 DONALDSON P838813 (inner) DCA-220ESEI Y06020 46617 DONALDSON P812363 (outer) DCA-400ESEI Y06020 46629 DONALDSON P836913 (inner) DCA-400ESEI Y06020 46628 DONALDSON P812559 (outer) (3) Checking on rubber suspension Check on the rubber suspension, whether it is damaged or deformed by the oil. Contact distributor or our office to replace the rubber suspension, if necessary. (4) Checking on nylon and rubber hose Check on the nylon and rubber hose, whether they are hardened or deteriorate. Contact distributor or our office to replace the nylon hose and rubber hose, if necessary. (5) Checking on lining Check on the lining, whether it deteriorates greatly, or it is stained by clinging of oil or the like, or it is removed. Contact distributor or our office to replace the lining, if necessary. - 50 -
6-2-5 Table of periodical maintenance and checking : Check or Clean 〇 : Replacement E Engine Generator List of maintenance and inspection daily every 250h Checking on oil level and stain of oil every 500h every 1000h every 2 year Checking on cooling water 〇 Checking on fan belt Checking on fuel and drain Checking on battery acid level Checking on for water and oil leakage Checking on bolts and nuts for loosness Checking on exhaust color, sound and vibration Checking on meters and warning lamps Drain the environment tank Drain water in fuel filter Clean air cleaner element Checking on specific gravity of battery Replacement of engine oil Replacement of engine oil filter element Replacement of PCV filter element Cleaning feed pump strainer Cleaning radiator and intercooler Replacement of fuel filter 〇 〇 Cleaning fuel tank Replacement of air cleaner element Inspection of engine valve clearance Adjust fuel injection nozzle Inspection of timing of fuel injection Checking on rubber suspension Checking on nylon and rubber hose Checking on lining Checking on insulation resistance Checking on terminal and connected section Checking on the operation of the leakage relay 〇 〇 〇 〇 Contact distributor or our office. It shortens it by the situation of the management replenishment of the fuel. - 51 -
7. TROUBLESHOOTING - 52 -
8. PRINCIPAL DATA 8-1 Readings on gauges E Marking Reading Unit Engine speed 1500 min -1 Hour meter Adding up H Engine temperature below 95 C Engine oil pressure Between 2 and 5 1) x100kpa Battery charging voltage more than 26.0 V Frequency 50 Hz Load current Below max. rating A Voltage indicates Phase-to-phase voltage V 1) If the engine is cold, the pressure may be higher during starting. 8-2 Setting of switches Switch Function Breaks at Unit Engine oil pressure Shut-down 1.0 100kPa Engine coolant temperature Shut-down 105 C 8-3 Reference conditions Absolute inlet pressure... 100kPa Relative air humidity... 60% Air inlet temperature...27 C Generator load...continuous 8-4 Limitations Maximum ambient temperature...40 C(220ESEI) 35 C(400ESEI) Maximum altitude 1000m Maximum relative air humidity......85% - 53 -
8-5 General specifications DCA type 220 400 1. Engine Isuzu, type 6UZ1 6WG1 No-load speed (50Hz), approx.min -1 1560 Load speed (50Hz), approx..min -1 1500 Electrical system..v 24 Batteries: Number 2 Voltage.....V 24 Capacity..Ah 150 2 200 2 Oil circuit capacity...l 41 55 Cooling circuit capacity...l 54 60 Fuel tank capacity, approx......l 460 490 2. Generator Type DF-2400I DF-4400I Rated output 50Hz...kVA 200 350 Voltage (range), line-to-neutral 50Hz...V 220 / 231 / 240 Voltage (range), line-to-line 50Hz...V 380 / 400 / 415 Frequency...Hz 50 Speed (50/60Hz) min -1 1500 Power factor... 0.8 Number of phases.. 3 phases + neutral Winding connection.... star Temperature specification. C -5~40-5~35-54 -
DCA type 220 400 E Insulation...Class F Insulation armature winding class... F Insulation field winding, class.... F Sensitivity of residual current relay.ma 30 Maximum diffusion resistance of earthing rod...ω 500 Setting of main circuit breaker A 350 600 3. Unit Length, approx.. mm 3790 4620 Width, approx....mm 1450 1450 Height, approx... mm 2000 2200 Net mass (dry), approx......kg 3870 5460 8-6 Conversion list of SI units into UK/US units 1 bar = 14.504 psi 1 kw = 1.341 hp (UK and US) 1 m = 3.281 ft 1 N = 0.225 lbf 1 g = 0.035 oz 1l = 0.264 US gal 1 mm = 0.039 in 1 Nm = 0.738 lbf.ft 1 kg = 2.205 lb 1l = 0.220 lmp gal (UK) 1 m 3 /min = 35.315 cfm x C = (32+1.8x) F 1 km/h = 0.621 mile/h 1l = 0.035 cu.ft 1 mbar = 0.401 in wc t1 C = 1.8 F 1 bar = 100kPa - 55 -