Denyo DCA-600P Instruction Manual
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Denyo DCA-600P Instruction Manual

Denyo DCA-600P Instruction Manual

Engine-driven ac generator
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No.C48431 00604A
INSTRUCTION MANUAL
E N G I N E - D R I V E N A C G E N E R A T O R
DCA-600P
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

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  • Page 1 No.C48431 00604A INSTRUCTION MANUAL E N G I N E - D R I V E N A C G E N E R A T O R DCA-600P IMPORTANT: READ AND UNDERSTAND THIS MANUAL CAREFULLY BEFORE USE OF THIS MACHINE.

  • Page 2: Table Of Contents

    CONTENTS SAFETY PRECAUTIONS FOR GENERATORS ..............1. DCA series ........................General ........................Machine structure ....................Machine appearance and internal component devices ........... Control switches and meters ................... 10 1-4-1 Engine start/stop controls ..................1-4-2 Engine indicators ....................1-4-3 Generator controls and indicators ................19 2.
  • Page 3 FOREWORD • We are very thankful for your special choice of our MACHINE in the market. • 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. •...

  • Page 4: Safety Precautions For Generators

    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.
  • Page 5 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. Parts name Parts number CAUTION : Instruction manual...
  • Page 6 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.
  • Page 7 WARNING: DIESEL CAUTION: FUEL can cause fire HOT COOLANT can or explosion. cause severe scalds. Fuel and oil are flammable. Incorrect handling If the radiator cap is opened while the water results in danger of ignition or fire. temperature is high, steam or hot water will spout •...
  • Page 8 CAUTION: Operator. CAUTION: Noise. Do not operate the machine if operator is tired too This machine generates large noise if the door is much or drinks some alcohol or take some drugs. open. Surrounding to large noise may cause hearing •...
  • Page 9 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 DANGER: Electric shock...

  • Page 10: Dca Series

    • The drain plugs for engine oil, cooling water and fuel(option) are located at the base side under the machine. Tags of their respective names are attached there. Fig. 1 Model DCA-600P Parts number AC generator Diesel engine...
  • Page 11 Fig. 2 Model DCA-600P Parts number Parts number Hanger Radiator cooling water drain plug Radiator cooling water refilling port Engine exhaust port (without muffler) Fuel tank refilling port (with fuel tank) Engine exhaust port (with muffler) Fuel drain plug (with fuel tank)

  • Page 12: Control Switches And Meters

    • 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-600P Parts number Parts number Frequency meter Pilot lamp Ac ammeter (U) 9.
  • Page 13 1. Operation switch The switch is 2-position switch which can be operated with its specific key only. 1) OFF/STOP OFF/STOP 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. OPERATION　SWITCH 2) RUN OFF/STOP...

  • Page 14: Engine Indicators

    1-4-2 Engine indicators 5. 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 engine oil pressure ×100kPa battery charging voltage engine coolant temperature ºC 1 - Engine Speed...
  • Page 15 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-600P turned-on Fuel level (L) 450 to full...
  • Page 16 (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.
  • Page 17   (6) The hour meter has an internal battery The engine monitor incorporates both a rechargeable internal battery as well as a charging circuit. While the generator is not in operation, the engine monitor will still indicate the hours operated via its internal battery.
  • Page 18 8. Switch and Lamp for Electronic Governor Controller (in the control box) SHUTDO WN　 LAMP ACTIO N ALERT　 L AMP F AUL T RESET 50Hz ISOCHRONOUS 60Hz DROOP WARNING　 L AMP DIAGNOSTICS　 L AMP FREQUENCY ISOCHRONOUS-DROOP CHANGE-OVER SWITCH CHANGE-OVER SWITCH (1) Isochronous-Droop Change-over switch The generating set can change the governor control between ISOCHRONOUS...
  • Page 19 (3) Diagnostic Lamp This lamp is sometimes called the check engine light. The diagnostic lamp is used to warn the operator of the presence of an active diagnostic code. The lamp may not be included in all applications. DIAGNOSTICS　LAMP (4) Fault Reset In case turn off the Diagnostic Lamp, push this button.
  • Page 20 Settings for the Monitoring System Parameter State Trip Point Delay Time Low Engine Oil Pressure 300 kPa Warn Operator 60 seconds (43.5 psi) 250 kPa Action Alert Always On 2 seconds (36.3 psi) 200 kPa Engine Shutdown Always On 2 seconds (29.0 psi) High Engine Coolant Temperature °C (219°F)

  • Page 21: Generator Controls And Indicators

    1-4-3 Generator controls and indicators 9. Frequency meter This meter indicates the frequency of the outputted voltage. Make sure that it reads 50Hz or 60Hz when running. 10. Ammeter (U, V, W) This meter indicates the current going to the connected load. It must not exceed the rated current.

  • Page 22: Transportation, Storage And Installation

    TRANSPORTATION, STORAGE AND INSTALLATION 2-1 Safety precautions for transportation, storage and installation 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 of base. •...

  • Page 23: Transportation

    For dimensions and weight of the machine, refer to “7 Principal Data”. See Fig 5 for the center of gravity. (without optional parts) Fig. 5 Model DCA-600P 1970 mm 20 mm 700 mm • When lifting the machine, use the hanger of base.

  • Page 24: Preparing For Operation

    3. If it is impossible to run the engine regularly, extra precautions must be taken. 1) Consult the instruction manual for the engine. 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.

  • Page 25: Installation

    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 46°C, humidity of 85% or lower and altitude of 1000m or ower.
  • Page 26 5. Do not direct the exhaust towards passers-by or residences, etc. 6. Install an exhaust pipe of sufficient diameter to let the engine exhaust gas out directly. 7 . 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.
  • Page 27 Model DCA-600P Fig. 7 1. Oil level gauge 6. Alternator 2. Oil refilling port cap 7. Fuel pre filter 3. Oil drainr 8. Fuel filter 4. Expansion tank cooling water 9. Air cleaner 5. Fan belt - 25 -...

  • Page 28: Checking After Installation

    2-4-2 Checking after installation (1) Check engine oil (Read the instruction manual for the engine furnished separately.)   ① Check the level of engine oil by the dipstick. Make sure the oil level is always between H and L. ...
  • Page 29 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.
  • Page 30 (9) 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. (10) Removal of foreign objects in machine •...

  • Page 31: Operation

    3. OPERATION 3-1 Safety precautions for operation 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.
  • Page 32 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.

  • Page 33: Connecting The Load

    3-2 Connecting the load 3-2-1 Precautions in connecting the load • 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.

  • Page 34: Selection Of Cables

    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.

  • Page 35: Connecting The Load

    3-2-4 Connecting the load 1. Check whether frequency, voltage and current conform with the ratings of the generator. 2. Install for the load cable, without excessive length, and lay it out in a safe way without forming coils. 1. Cable clamp 2.

  • Page 36: Grounding

    3-3 Grounding Execute the grounding certainly to prevent the electric shock by leak. 1. Case grounding of the machine Use the grounding wire which sectional area conforms to the local rule. Provide the grounding resistance which conforms to the local rule. 2.
  • Page 37 2. Checking the cooling water in engine radiator • Remove the filler cap and check that the water level is bottom of the filler pipe. Refill if short. • Use soft water as engine cooling water. Use anti-freeze solution where the atmospheric tem- perature is low.

  • Page 38: Instruction For Fuel Device

    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. 3-4-2 Instruction for Fuel Device (1) Setting Procedure for Separate Tank ...

  • Page 39: Starting

    3-5 Starting 1. Insert the key in the operation switch. Turn the key to RUN keep on pushing start button to start engine. • Do not engage the starter for more than 10 seconds at a time; if the engine does not fire, wait 2 minutes before restarting.

  • Page 40: During Operation

    3-6 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. •...
  • Page 41 Table of protection device turn OFF indicate by action Stop the the circuit warning function warning engine breaker lamp – – set point: 300kPa ※ oil pressure failure (OIL PRESS.) – stop  set point: 200kPa high jacket water – –...

  • Page 42: Fuel, Coolant And Lubricants

    4. FUEL, COOLANT AND LUBRICANTS Engine oil selection: For engine oil, use API grade : CG-4, ACEA grade : E5 or EMA grade : DHD-1. The brands/types of oil described PERKINS’s instruction manual can be used regardless of specified API, ACEA or EMA grade above. Oil viscosity: Engine oil viscosity largely affect engine startability, performance, oil consumption, speed of wearing and occurrence of seizure, etc.
  • Page 43 [ NOTE ]: Operating Direct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection. Percentage of Sulfur in the fuel Oil change interval Lower than 0.5 Normal 0.5 to 1.0 0.75 of normal...
  • Page 44 The modern, high pressure fuel injection system used on the 2800 Series engines a high level of fuel cleanliness to ensure correct operation and reliability. The fuel must conform to all aspects of the ASTM D975 specification, but in particular to the requirement for number 2-D to have less than 0.05% water and sediment.

  • Page 45: Periodic Checkup And Maintenance

    5. PERIODIC CHECKUP AND MAINTENANCE 5-1 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.

  • Page 46: Periodic Chechup

    • 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. The periodic checkup and maintenance are outlined. Read the relevant section beforehand.

  • Page 47: Checking/Every 250 Hours

    5-2-2 Checking/every 250 hours (1) Cleaning of air cleaner element This element should be cleaned, regardless of operating time, when the red piston of service indicator locks in the visible position. - Dry dust clings on element - Remove the air cleaner element and clean the element with dry and clean compressed air.

  • Page 48: Checking/Every 500 Hours

    5-2-3 Checking/every 500 hours Checking/every 250 hours is also required. (1) Inspection, adjustment and replacement of alternator and fan belt 1. Inspection Check all drive belts and replace a belt if it is worn or damaged. Where more than one belt is used between two pulleys, all of the belts must be replaced together.
  • Page 49 (2) 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"...
  • Page 50 (4) Replacement of fuel filter element (primary filter and secondary filter) 1. Replacement of Primary filter [ NOTE ]: Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over discon- nected fuel system component.
  • Page 51 [ NOTE ]: The filter element for the secondary fuel filter is different from the element for the primary fuel filter. Ensure that the correct elements are installed into the filter system. ④ Ensure that the insert (4) is the same shape as the tab (3). ⑤...
  • Page 52 ⑨ Continue to eliminate air from the fuel system if these events occur: • The engine starts, but the engine does not run evenly. • The engine starts, but the engine continues to misire or smoke. ⑩ Run the engine with no load until the engine runs smoothly. Parts number of fuel primary filter cartridge: Parts number Manufacture...

  • Page 53: Checking/Every 1000 Hours

    5-2-4 Checking/every 1000 hours Checking/every 250 and 500 hours is also required. Cleaning inside fuel tank (Only with fuel tank) Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. - 51 -...

  • Page 54: Table Of Periodical Maintenance And Checking

    5-2-5 Table of periodical maintenance and checking : Check or Clean : Replacement 〇 List of maintenance and inspection daily every every every every 250h 500h 1000h 2 year Checking on oil level and stain of oil ◇ Checking on cooling water ◇...

  • Page 55: Troubleshooting

    6. TROUBLESHOOTING - 53 -...

  • Page 56: Principal Data

    7. PRINCIPAL DATA 7-1 Readings on gauges Marking Reading Unit Engine speed 1500 / 1800 Hour meter Adding up Engine temperature below 95 °C Engine oil pressure Between 2.0 and 6.0 x100kPa Battery charging voltage more than 26.0 Frequency 50 / 60 Load current Below max.

  • Page 57: General Specifications

    7-5 General specifications Voltage class 200V 400V 1. Engine Perkins, type 2806A  No-load speed (50/60Hz), approx………….min 1560 / 1870 (Droop)   1500 / 1800 (Isochronous) Load speed (50/60Hz), approx……………..min 1500 / 1800  Electrical system……………………………..V  Batteries: • Number ...

  • Page 58: Conversion List Of Si Units Into Uk/Us Units

    Voltage class 200V 400V Insulation………………………………..Class   Insulation armature winding class…………..  Insulation field winding, class……………...….   Setting of main circuit breaker………………A 1600  Length, approx…………………………..…mm 3630  3. Unit (without optional part and lifting hunger) Width, approx…………………………...….mm 1725 ...

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