Denyo DCA-30ESX Instruction Manual

Denyo DCA-30ESX Instruction Manual

Diesel generating sets

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I N S T R U C T I O N
D I E S E L
Before using, be sure to read this manual for the sake of safety.
Be sure to observe the items under symbol marks
" A
and
Always keep this manual at your machine for the sake of safety.
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Киргизия (996)312-96-26-47
D E N Y O
G E N E R A T I N G
CAUTION"
for the sake of safety.
D C A - 3
D C A "
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M A N U A L
O E S X
4
O E S X
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S E T S
■ A WARNING'
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Ярославль (4852)69-52-93

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Summary of Contents for Denyo DCA-30ESX

  • Page 1 Хабаровск (4212)92-98-04 Иваново (4932)77-34-06 Мурманск (8152)59-64-93 Челябинск (351)202-03-61 Саратов (845)249-38-78 Ижевск (3412)26-03-58 Набережные Челны (8552)20-53-41 Севастополь (8692)22-31-93 Череповец (8202)49-02-64 Иркутск (395) 279-98-46 Нижний Новгород (831)429-08-12 Ярославль (4852)69-52-93 Симферополь (3652)67-13-56 Казахстан (772)734-952-31 Киргизия (996)312-96-26-47 Таджикистан (992)427-82-92-69 Эл. почта: dne@nt-rt.ru || Сайт: https://denyo.nt-rt.ru/...
  • Page 2: Safety Precautions

    1. Safety Precautions 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 3: Safety Label

    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. No.
  • Page 4 WARNING ENGINE EXHAUST can kill. Ё Insufficient ventilation m ay lead to death due to lack o f 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.
  • Page 5: Electric Shock Can Kill

    WARNING ELECTRIC SHOCK can kill. Ш Do not touch the output term inals 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 6 WARNING ELECTRIC SHOCK by leak can kill. ! Improper grounding m ay lead to death due to electric shock. * Be sure to execute the grounding of the machine and the load according to the local rule. WARNING MOVING PARTS can cause severe injury. I Rotary unit w hich runs at a high speed is located in the machine, (Note that it i? very dangerous i f you touch it,)
  • Page 7 Ж WARNING D IE S E L F U E L can cause fire o r explosion. I Fuel and oil are flam mable. Incorrect handling results in danger o f ignition or fire. * When fuel needs to be supplied to the machine, be sure to stop the engine.
  • Page 8 Ж CAUTION Sta citing I Improper stacking o f m achines m ay cause falling or dropping accidents. W hen stacking other m achines on .this m achine, be sure to observe the following points. * Check that the bonnet of the machine is free from damage and that the fixing bolts are not loosened and missing.
  • Page 9 CAUTION B A T T E R Y Щ B attery generates flam mable gases. Im proper handling m ay 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.
  • Page 10 Ж CAUTION Operator Щ D o n o t operate the m achine, if operator is tired too m uch or drinks some alcohol or take som e drugs. * Otherwise, it may cause unexpected accidents or injury. M 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.
  • Page 11 А CAUTION Transportation Ш 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.
  • Page 12 Construction Outline and part names (DCA-40ESX) 7. fuel in 1. oil drain plug 8. fuel drain plug 2. exhaust gas outlet 9. coolant drain plug 3. hanger rod 4. support hook 10. engine indicator 11. operating panel 5. coolant in 12.
  • Page 13 6. diesel engine air cleaner 7. radiator 2. oil filter 8. oil level gauge 3. fuel filter 9. control box 4. reserv e tank 5. AC generator 10. fuel tank 11. battery - 12 -...
  • Page 14 Operating panel, control panel and part names (DCA-40ESJQ CONTROL PANEL OPERATING PANEL frequency meter engine indicator AC ammeter indicator: AC voltmeter engine speed, oil press, water temp, voltage regulator battery charging voltage circuit breaker (1-phase) integrating time pilot lamp luel level indicator panel light warning lamps earth leakage relay...
  • Page 15: Engine Indicators

    Meters Engine indicators Fig.4 (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 XlOOkPa battery charging voltage engine coolant temperature °C...
  • Page 16: Fuel Level Indicator

    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. DCA-30ESX DCA-40ESX Numbers of...
  • Page 17: Hour Meter

    (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.
  • Page 18 (5) 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. While the generator is in operation, the internal battery recharges.
  • Page 19 Generator indicators (X) Frequency m eter This meter indicates frequency o f the output Ф ¥ ¥ voltage. Г Make sure that it indicates 50Hz or 60Hz during ® © operation. » . 50Hz 60Hz (2) AC am m eter This meter indicates AC current flowing into the connected load.
  • Page 20 Indication/alarm lamp (1) 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.
  • Page 21 © High fuel filter water level (FUEL FILTER WATER LEVEL) ( FUEL FILTER) This lamp turns on when the water level in the fuel filter would W A T E R LEVEL — —— rise. Drain the water in the strainer soon after the lamp would turn on. (for 30ESX) ^ ..—..
  • Page 22 Use of switches and controllers Switches (l)S ta rte r switch Functions: (D 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. ® Run This switch should be set in this position when the machine is in operation.
  • Page 23 (3) Speed control device ■ Throttle lever This lever is used to control the engine speed. Set the START/IDLING lever at the "START/IDLING" position for startup or warm up/cooling operation of the engine and at the "RUN" position for constant speed operation o f the This screw is used to adjust the frequency.
  • Page 24 Element located into the Fuel Pump, or replace it to new one. P arts number of fuel filter elem ent located into the fuel pump: manufacture Parts number of manufacture Model name Parts number DCA-30ESX Y06020 42425 894437-0220 ISUZU DCA-40ESX Voltage regulator and overcurrent relay (1) Voltage regulator Tliis regulator is used to control the output voltage.
  • Page 25: Transportation And Installation

    3. Transportation and installation Transportation of machine CAUTION Transportation 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.
  • Page 26: Installation Of Machine

    Installation of machine WARNING ENGINE EXHAUST kill. H Insufficient ventilation m ay lead to death due to lack o f 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.
  • Page 27: Installation Procedure

    Installation procedure * Install the machine horizontally on a solid foundation. * Provide a space of more than about lm at the side of the control panel and fuel feed port to ensure correct operation and supply. * Provide a space o f more than about 1.2m on the left and right sides for check of the engine, oil supply and cable connection work.
  • Page 28: Cables To Be Used

    Connecting the ioad Cables to be used Selection of cables: Use cables having sufficient size in consideration o f the allowable current of the cables and the distance between the machine and the load. If the load current exceeds the allowable current o f cables, the cable may be damaged by overheat.
  • Page 29: Connecting The Load

    Connecting the load ELECTRIC SHOCK can kill. I D o n o t touch the output term inals during operation to prevent decease due to electric shock, * When a wiring work is required, be sure to turn OFF the circuit breaker and stop the machine. * When operating the engine, close the output terminal cover.
  • Page 30 Fastening the output terminal [Note] In connecting the load, tighten locking bolts securely with a spanner or the like to prevent burning. Connecting three phase output terminal Connect the load to the output terminal after confirmation of load phase and voltage. Use 0/U ,0 W и...
  • Page 31 (3) Precaution in load connection Ф Be sure to provide a switch for taming the load ON and OFF between the output terminal block and the load. Note that the use of the breaker of the machine for taming the load ON and OFF may result in breaker failure.
  • Page 32: Earth Leakage Relay And Grounding

    4-3 EARTH LEAKAGE RELAY and Grounding WARNING ELECTRIC SHOCK by leak can kill. Ш Im proper grounding m ay lead to death due to electric shock. Because the device for leakage protection does n o t operate effectively. * Grounding terminal for the earth leakage relay, case grounding terminal and case of the load are grounded.
  • Page 33 (2) Grounding Ground as following to operate the earth leakage relay certainly. Ш Grounding o f the machine Ground the grounding terminal for earth leakage relay and case grounding terminal according to the below. ©Grounding of the grounding terminal for earth leakage relay If grounding described below does not comply with the local rule, stricter of the...
  • Page 34 [Note] The installation of a leakage relay on the machine can not become a reason for elimination of the need for the load side grounding. The load side grounding is indispensable for earliest possible detection of any leakage caused in the generator. The absence of such grounding requires any leakage to be detected by current flowing through the human body and is very dangerous because the sensitivity o f leakage relay provided on the machine is not sufficient for detection o f such current.
  • Page 35 H Operation check For safety reasons, check on the operation of the leakage relay at the startup of the machine according to the procedure described below: © S tart up the machine according to Г5-2 Startup J © M ake sure that all breakers of the load side are "OFF".
  • Page 36: Operation

    5. Operation - From pre-start check to shut down - Be sure to check the machine prior to starting. Pre-start check : Check oil, cooling water, fuel and so on. Periodical check: Check each part of the machine according to operating time. Startup: Check the surroundings o f the machine for safe operation.
  • Page 37 Check on engine oil (lubricating oil) Check on engine cooling water Checking on fan belt Checking on fuel Checking on battery aeid Checking on grounding for electric shock protection Checking for leakage of oil and water Checking for loose parts Removal o f foreign objects in machine Inspection: Checking on engine oil...
  • Page 38 Check on engine cooling water (Read the instruction manual for the engine furnished separately.) WARNING H O T C O O L A N T can cause severe scalds. 1 I f the radiator cap is opened w hile the w ater tem perature is high, steam or hot w ater will spout out.
  • Page 39 (middle of belt) with your thumb. The bend should be within the range of 10-15mm. Parts number of fan belt : Model name Parts number manufacture Parts number of manufacture DCA-30ESX Y06020 11432 ISUZU 897322-6800 DCA-40ESX Y06020 15259 ISUZU 897232-2520...
  • Page 40 Check on battery acid CAUTION BATTERY Ш The battery acid is dilute sulfuric acid. Improper handling will cause unexpected bums. * When the battery acid gets on your clothes or skin, wash it out with a large volume o f water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor.
  • Page 41 (6) Check grounding for electric shock protection Make sure that the case grounding of the grounding ta r и Inal machine and the load are certainly. fo r earth leakage relay case grounding Do not ground directly ГО] terminal. te rn in a l grounding y irs Check for leak of water and oil Check the machine for the trace of leak o f oil or water.
  • Page 42 Startup Following is flow o f startup. I ? , ' circuit breaker : OFF throttle lever : START / IDLING When it is cold. warm up operation : about 5 minutes warm up operation : sufficiently throttle lever : RUN adjustment of speed adjustment of voltage circuit breaker: ON...
  • Page 43: Start-Up Procedure

    Ж CAUTION * Do not start the engine when the machine and the load circuit breaker are ON, or else, power is supplied to the load at the start of the engine which causes electric shocks or trouble in the load. Startup procedure: (1) Make sure that the circuit breakers o f the machine and the loads are all OFF.
  • Page 44 After engine starts up, release the starter key. Check the Oil pressure failure lamp goes off. Drive the machine for warming up the engine for about 5 minutes at the "START / IDLING" position of the throttle lever. After wanning up the engine, set the throttle lever to the "RUN"...
  • Page 45: Handling During Operation

    Handling during operation Checking after startup (D Make sure that each meter and lamp are normal. normal : warning lamp is all off © Make sure that the color of exhaust gases from the engine is normal. Check for unusual noise and vibration. Color of exhaust gases - Colorless or light blue: Normal...
  • Page 46 Shut down Turn OFF the circuit breaker of the load. circuit breaker of the load ii j j . Turn OFF the circuit breaker of the machine. Circuit breaker o f the machine Set the throttle lever in "START / IDLING" position and put the machine in cooling operation for about 5 minutes.
  • Page 47: Protection Device

    Protection device Protection devices and emergency stop devices are provided for protection o f the machine against trouble during operation. When the running caution lamp lights, stop the engine immediately. Check and remove the cause of trouble. Table of protec ion device action turn OFF the stop...
  • Page 48: Engine Oil

    S A E 1 5 W - 4 0 ------------------- [N o te]: Do not mix with different kind of oil, or else, it deteriorates the oil quality, (3) Quantity of replacement oil Total oil quantity DCA-30ESX 1 0 . OL (0,3) DCA-40ESX 1 3 . 2 L...
  • Page 49 In case o f replenishment, use LLC o f the same brand and the same density. Normally LLC should be replaced every 2 year. Total quantity of cooling water Total cooling water quantity DCA-30ESX 1 0 . 9 L (0.9) DCA-40ESX 1 5 .
  • Page 50 Handling of battery CAUTION BATTERY Ё Ш Battery generates flam m able gases. Improper handling m ay 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 -).
  • Page 51 Caution on battery charge — Charging of loaded battery Disconnect the wiring cable from the battery terminals before charging. (Otherwise, the alternator may be damaged due to unusual voltage applied to the alternator) When disconnecting the wiring cables from the battery terminals, remove the ground cable first.
  • Page 52 Connection of booster cable* and installation When the engine is started using booster cables, connect the cables as follows. Connection of booster cable ф Connect the clip of the booster cable "A" to the terminal of the machine in trouble. Ф...
  • Page 53 8. Periodical checking and maintenance (Read the instruction manual for the engine furnished separately) WARNING MOVING PARTS can cause severe mjury. I - Rotary unit which moving parts at a high speed is located in the machine. Care should be taken during operation. * When the machine needs checking or maintenance, be sure to stop it in advance.
  • Page 54 CAUTION can burn skin. HOT PARTS §9 High temperature parts are located in the machine. Care should be taken during operation. * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside of the bonnet is still hot.
  • Page 55 ж CAUTION Sign for maintenance * During checking or maintenance, be sure to put up a sign "Under maintenance"' at a conspicuous place such as the starter switch to prevent the machine from being operated by other persons, CAUTION clothes Safety * During checking or maintenance, be sure to put on suitable clothes and protectors.
  • Page 56: Maintenance Schedule

    Maintenance schedule 50 hours: Checking/first 50hours * Replacement of engine oil * Replacement of engine oil filter element 250 hours: Checking/every 250 hours Replacement of engine oil (for 40ESX) Cleaning o f air cleaner element * Measurement of generator insulation resistance (once a month) * Checking on battery specific gravity 500 hours;...
  • Page 57 Then, check to see that oil is supplied to the level between H and L. Parts number of oil filter cartrid. ye : Model name Parts number manufacture Parts number of manufacture DCA-30ESX У06020 41214 ISUZU 897049-7081 DCA-40ESX Y06020 41217 ISUZU...
  • Page 58: Checkin G/Every 250 Hours

    Checkin g/every 250 hours (1) Replacement of engine oil Replacement is refer to Г 8-2.(l) Replacement of engine oil J . Excepting that the 3GESX unit should be at the interval 500 hours, Cleaning of a ir cleaner element This element should be cleaned, regardless of operating time, when the warning lamp of "Air filter blinding"...
  • Page 59 M easurement of insulation resistance. Ж WARNING loll. ELECTRIC SHOCK can * Measurement should be made after the machine stops. - Using a 500V insulation resistance tester, make a check once a month to ensure that the insulation resistance is more than 1M £2. In case o f measuring with an insulation resistance tester over 500 VDC current, disconnect all connectors from the AVR located in the control box before measuring.
  • Page 60 Check battery specific gravity. If battery is likely to be discharged due to failure in startup of the engine, measure the specific gravity of battery acid. The relation between battery charge condition (charging rate) and specific gravity is as shown below. Liquid temp.
  • Page 61: Checking/Every 500 Hours

    - When mounting, tighten the cartridge about from 1/2 to 3/4 turn by hand after the packing is DCA-30ESX fitted to the seal of the filter base. After the cartridge is replaced, discharge air in the fuel piping.
  • Page 62 . (3). 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 ' J V “ a place about 1.5m away to prevent damage to the fin or tube. Checking fo r term inal and connection of the circuit.
  • Page 63: Checking/Every- 1000 Hours

    (2) Replacement of a ir 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-30ESX Y06020 46366 DONALDSON P82-7653 DCA-40ESX Y06020 46365 DONALDSON...
  • Page 64 S-6 Table of periodical maintenance and checking 0:C h eck or Clean OiReplacement fViOnly first time first every every every every List of m aintenance daily 5 Oh 250h SOOh lOODh 2 year and inspection О Checking on oil level and stain of oil о...
  • Page 65 Troubleshooting ------- Ж WARNING MOVING PARTS can cause severe injury. Ш Rotary unit which moving parts at a high speed is located in the machine. Care should be taken during operation. * When the machine needs checking or maintenance, be sure to stop it in advance. WARNING kill.
  • Page 66 Ж CAUTION НОТ PARTS сад burn skin. Ш High temperature parts are located in the machine. Care should be taken during operation. * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside o f the bonnet is still hot.
  • Page 67 Phenomenon Assumed cause Action Charge or Discharged battery replace Cell m otor Detached or loosened or corroded Repair will not run battery terminal or revolution F use blow Replace Engine will speed is low Im proper starter switch Replace n o t start up Im proper starter Replace Broken lead wire...
  • Page 68 Assumed cause Action Phenomenon V oltmeter failure Replace Contact AVR failure Voltage goes too high distributor or VR failure our office Contact Burned rotary rectifier distributor or AVR failure Applied load causes load our office Burned main fieldt exciter field voltage drop wiring Balance...
  • Page 69: Long Term Storage

    Long-term storage When the machine is to be stored for a long period of time, choose a cool place free from moisture and dust, and observe the following points. (1) Remove dirt clinged the machine and clean it thoroughly. If painting is peeled off, it should be repaired. (2) Remove the battery from the machine.
  • Page 70: Service Data

    Service data 11-1 Specifications D C A - 3 O E S X D C A - 4 O E S X MODEL MODEL DB-05071 DB-0667I 5 0 /6 0 H z FREQUENCY с 2 4 /3 0 kVA 3 3 / 4 0 kVA RATED OUTPUT RATED VOLTAGE 1 0 0 /2 0 0 V...
  • Page 71 11-2 AC generator specifications (for custom voltage) DCA-30ESX 60Hz 50Hz S ated output (kVA) 110/220 100/200 110/220 Rated voltage (V) 100/200 Rated current(A ) DCA-40ESX 50Hz 60Hz Rated output (kVA) 100/200 110/220 100/200 110/220 Rated voltage (V) Rated cuirent(A)
  • Page 72: Outline Drawing

    11-3 Outline drawing DCA-30ESX j - P H A S E O W I R E S ) O U T P U T T E R M I N A L H E A T E D A I R A N D...
  • Page 73 11-4 Generator connection diagram DCA-30ESX ш и О 4Э * ■ * О l> ас к К < — ► о «j tn Ш in Ft О e_> С* c< й -< о о о >* О -< ► - 1 p i p i 4 —...
  • Page 74 MARK MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING ЕкАг БХСГТБЛ ARMATURE WINDING ExFS EXCITER FIELD WINDING R EC T IFIER AUTOMATIC VOLTAGE REGULATOR ' VOLTAGE REGULATING RHEOSTAT CT1, CURRENT TRANSFORMER 250/5A "£ AC. AMMETER 0 ~ 250V AC, VOLTMETER 0~30DV FREMIENCY METER 45 ~ £SH*...
  • Page 75 т о STARTED Ш Г С К 1. a i з АСС V ! 1 Е Ь S I Z E C O L O R C O D E I TJ « CDLOl v i s a t o t o a Э...
  • Page 76 т о STARTER srncu — ъ rfT fl- » W I R E S I Z E C O L O R C O D E 6 0 = m r r t ! ШL ЛИ C O l t m f f l t t l C O L d i У...
  • Page 77 Options instruction manual If equipment the option device to the machine after the purchase is required, contact distributor or our office. If the machine is modified an your own, the warranty of manufacturer will become in valid. 12-1 Fuel piping selector (1) Description o f the device The “Fuel piping selector”...
  • Page 78 To loaded fuel tank Outside of machine Outside fuel tank Fig.2 Use of outside fuel tank Outside of Inside of - 77 -...
  • Page 79 Санкт-Петербург (812)309-46-40 Иваново (4932)77-34-06 Мурманск (8152)59-64-93 Саратов (845)249-38-78 Челябинск (351)202-03-61 Ижевск (3412)26-03-58 Набережные Челны (8552)20-53-41 Череповец (8202)49-02-64 Севастополь (8692)22-31-93 Иркутск (395) 279-98-46 Нижний Новгород (831)429-08-12 Ярославль (4852)69-52-93 Симферополь (3652)67-13-56 Казахстан (772)734-952-31 Киргизия (996)312-96-26-47 Таджикистан (992)427-82-92-69 Эл. почта: dne@nt-rt.ru || Сайт: https://denyo.nt-rt.ru/...

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Dca-40esx

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