NO, 001 01 675 048 INSTRUCTION MANUAL Engine Generator MODEL: DCA - SERIES MODEL : DCA- 13 SPK ,DCA-15 SPK DCA - 25 SPK Denyo Asia Pte Ltd. HEAD OFFICE 27 Pioneer Sector 1, Jurong, Singapore 628433 Tel. : 65-8610058 Fax. : 65-7969067This Instruction manual givesa detailed description of the operation, routine inspection, maintenance, and troubleshooting of the generator, and other items required for properoperation, We therefore recommend that all users read this manual carefully before actually operating the generator to ensure proper operation. For detailed operation, disassembly. reassembly and repair of the engine, please refer to the "Engine Instruction Manual” supplied by the engine manufacturer.CONTENTS INTRODUCTION OF PRODUCTS... SAFETY PRECAUTIONS ..... MAJOR SPECIFICATIONS .. PREPARATION CAUTION FOR A.C. POWER SUPPLY... OPERATING PROCEDURES... STARTING AND OPERATING STOPPING THE ENGINE CAUTION WHILE OPERATING EARTH LEAKAGE RELAY MAJOR COMPONENT FUNCTION INSPECTION AND MAINTENANCE .... STORAGE... TROUBLESHOOTING... GENERATOR WIRING DIAGRAM. ENGINE WIRING DIAGRAM OUTLINE DRAWING ... SAFETY PRECAUTIONS FOR DIESEL GENERATING SET AND EQUIPMENT . 211. INTRODUCTION OF PRODUCT Thank you very much for purchace of our product DENYO GENERATING SET. This instruction manual is a guide to handle your best purchase, DENYO GENERATING SET, and hope you will read it caraefully for proper use of this machine. Then it will surely serve you for a long period of time. The DCA-13 SPK, DCA-15 SPK, and DCA-25 SPK, is emploied a new conception power generating system and has features as follows; (1) Maintenance-Free Design This high-performance brushless generator is virtually maintenance free. An unique maintenance system facilitates easy daily chek and routine servicing. 2) Voltage Regulation Less Than + 1.5% A high-performance Automatic Voltage Regulator (A.V.R.) maintains superb output stability by keeping voltage variation to under + 1.5% 3) Minimal Waveform Destortion ‘Adampercoil and a new generator design keep waveform destortion to negligible levels, even under SCR and compact X-Ray unit loads. (4) Continuous Long-Time Operation Long-Time operation has been accomplished by employing a fuel-saving engine and abig fuel tank. (5) Standard Emergency Stop Device An emergency stop device is built-in. It monitors water temperature, and oil pressure. When a malfunction is detected, engine stops automatically. (6) Compact & Double-Piling Design The generator are framed strongly enough to be stacked one on top of the other for efficient strong, (7) High Quality Design This generating set has been designed as a high quality portable power source for lighting facility, power tools, and other industrial and construction machinery. (8) Anautomatic air extraction device from fuel is standard equipment, enabling its an easy air-extractiona -uomeiado ayqerfar Pur ayes 203 [fam parpnus aq pnoys Koy, “szoy paytduuos are souToeu mo Jo ayty Bu0] pure uoesado apes soy uorMMeooud UELOdu Ayper2adg SNOILAVOUUd ALTAVS 7MAJOR SPECIFICATIONS ‘SPEC./ MODEL DCA- 13 SPK MODEL, DF-O140K Frequency (Ha) 50 60 Rated output (kVA) 708 i Rated Voltage (V) Rated current (A) 200 30.3 75 215 28.2 349 220 27.6 34.1 230 26.4 32.6 ra 240 25.3 31.3 ° 380 16.0 19.8 2 400) 15.2 18.8 fe 415, 14.6 18.1 ws 430) 14.1 75 2 440 13.8 17.0 a} 460) 13.1 16.3 480) 12.6 15.6 Number of phases. ‘Three phase, four-wire Power factor 0.8 (lagging) Britation Brushless type (with automatic voltage regulator) Number of poles, = Speed (min-) (rpm) 1500 1800 insulation Class F ‘AUX. AC Power (OPTION) Single-Phase 3 kW (1.5 KW x2) Model D 1403 - KA, Type Vertical, water-cooled, 4-eycle diesel Number of cylinders 3 [Bore x Stroke (mm) 80x 92.4 = [otal displacement 7-393 © [Rated output 1a) 70.1 124 = {ps} 03.7) (16.9) Batiory T2V~JOARX1 Fuel DIESEL FUEL ASTM NO. 2 or eq. Fueltank capacity (0 “Approx. 62 Tabrigant quantity (Ly “Approx 6.6 Coolant quantity —(U) ‘Approx. 4.9) Length (rm) 1400 © PWwiath (omy 650 “8 [Height (mimi 900 © [Dry weight (kay ‘Approx.490,SPEC / MODEL DCA - 15 SPK MODEL DF = 0170 Frequency (Hz) 50, 60 Rated output (kVA) 125 15 Rated Voltage (V) Rated Current (A) 200 36.0 433 215 33.6 40.3 « 220 328 394 ° 230) 31.4 37.7 F 240 30.0 36.0 < 380 18.9 22.8 « 400 18.0 21.7 w 415 17.3 20.9 z 430) 16.8 20.1 w 440 164 19.7 o 460) 15.7 18.8 480 15.0 18.0 Number of phases Three phase four wire Power factor 0.8 (lagging) Exitation Brushless type (with automatic voltage regulator) Number of poles 4 ‘Speed (min _) (rpm) 1500 1800 Insulation Class F ‘AUX. AC Power (OPTION)| Single phase 3 kW (1.5 kWx 2) Model D 1703 = KA Type Vertical, water cooled, 4 cycle diesel w [Number of cylinders 4 2 [Bore x Stroke (mm) 87x 924 = [Total displacement (L) 1647 © [Rated output (KW) 124 147 z (ps) (16.9) (20) w | Batery 12 V=70 Ah xd Fuel DIESEL FUEL ASTM NO. 2 or eq Fuel tank capacity _(L) ‘Approx. 62 Lubricant quantity (L) ‘Approx. 5.6 Coolant quantity (L) Approx. 4.9 Length (mm) 1450 + [Width (mm) 650 | w [Height (mm) 900 [Dry weight (ke) ‘Approx. 509| | i ‘SPEC./ MODEL DCA - 25 SPK MODEL DF-0270K Frequency (H2) 50 60 Rated output kVA) 20 2 Rated Voltage (V) Rated current (A) 200) nT 722, 215) 53.7 67.1 220) 52.5 65.6 230 50.2 62.8 « 240) 48.1 60.1 ° 380 30.4 38.0 ee 400 28.9 36.1 « 416 27.8 34.8 uw 430 26.8 33.6 2 440) 26.2 32.8 a 460 25.1 314 480 24.1 30.1 Number of phases Three-phase, four-wire Power factor 0.8 (lagging! Exitation Brushless type (with automatic voltage regulator) Number of poles a ‘Speed (min-) (rm) 1500 1800 Tnsulgtion Class F ‘AUX. AC Power (OPTION) ‘Single-Phase 3 KW (1.5 KW x2) Model V2203-KC Type Vertical, water-cooled, 4-cyele diesel Number of eylinders 4 wt [Bore x Stroke (mm) 87x 92.4 = otal displacement (©) 2.197 © | Ratedoutput ro 184 BT 2 (ps) (25.0) (32.2) Battery T2V - JOAN Fuel DIESEL FUEL ASTM NO. 2 or eq Fuel tank capacity (0) ‘Approx. 62 Tubficant quantity (0) ‘Approx 7.6 Coolant quantity —_(U) ‘Approx. 7.5 Length (mm) 1580 © width tram 650 [Height (mm) 900) o Dry weight (ka) ‘Approx-6004 PREPARATION 4-1 General Inspection Prior to Operation This fgenerator has been throughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occured in transit. Lubricating Oi Check oil level every day. Fill the engine crankcase with lubricating oil through the fillerhole, but do not overfill. Make sure the generating set is level. With the dipstick inserted all the way, see that the oil level is maintained between the two notches on the dipstick. oil pan capacity (liters) DCA - 13 SPK | DCA - 15 SPK' DCA 25 SPK upper level 56 76 lower level 43 58 43 44 ‘The oil listed below is recommended to ensure proper engine performance. Use class CC or higher grade motor oil. Summer: SAE30 Winter =: SAE 10W-30 Fuel Check the fuel level before engine starting. Fill the fuel tank with clean and fresh diesel fuel. Donot overfill the fuel tank. Cooling Water See the water level in the reserve-tank (sub-tank) and be sure that it is maintained between "F" and "L" marks. Fill the tank and radiator with clean water, ifnecessary. -DANGER- NEVER fill the radiator while the engine is running oritis hot. Hot water may spread out from the filler hole. * Drainage Drain the water throught the water drain and open the radiator cap for quick drainage. * Antifeeze Use antifreeze in cold operating condition, 645 Battery Proper maintenance of the battery is extremely important to ensure smoth, starting and long service life. Check the specific gravity, level of electrolyte and output voltage every 50 hours of operation, If the specific gravity is 1.28 (at 20°C), the battery is adequately charged. Ifitis 1.245 or less, recharging is necessary. The electrolyte must always cover the plates. Ifthe plates are exposed to air fora long time, damage will result. Apply a thina thin coat of grease to ensure agood connection. 5. CAUTION FOR AC POWER SUPPLY Sel 52 5-3 5-5 On connecting a 3-phase load to the output terminals, securely tighten locking bolt witha spanner to prevent it from burning. Make sure to switch the circuit breaker to the "OFF" position prior to connecting the load. Never connect the load with the circuit breaker "ON", Electric shock and possible damage to the generating set may occur. Total wattage of the loads should not exceed the rated output capacity of the ‘generating set When connecting a single-phase load to the output terminals, keep all loads well-balanced. Unbalanced distribution of the loads may cause a instable output voltage. Connecting the load paw ° [EWS] — kphase, 200V/215V/220V/230V/240V/380V/ FR 400V/415V/430V/440V/460V/480V + TV WS] phase, LISV/12AV/IZTV/IS3V/IZ9V/220V/ 2 230V/240V/248V/254V/266V/277V bie wees gv? L-phase, 200V/215V/220V/230V/240V/380V/ f 400V/415V/430V/440V /460V/480V. }6. OPERATING PROCEDURES 6-1 Before Starting (1) Circuit Breaker Check Be sure to disconnect the electrical load and switch the circuit breaker to the "OFF" position prior to starting the engine. ‘Never start the engine with the circuit breaker "ON", | { ij (2) OilCheck Check the lubricating oil level prior to starting the engine, making sure the generaing set is level. The oil level must be maintained between the two notches on the dipstick. ‘When there is not enough lubricating oil, fill the crankcase with high grade motor oil. Use a high quality detergent oil classified CC or CD. -CATION- ‘NEVER start the engine when the oil level is below the lower mark onthe dipstick, ) Fuel Check ‘Cheek the fuel level by the fuel gauge. When the fuel is low, fill the fuel tank with clean and fresh diesel fuel. (4) Battery Check Check the level of electrolyte, making sure the generating setis level. 7. STARTING AND OPERATING 7-1 Tur the Fuel Cock Level to the "ON" position 7-2. Tur the Battery Switch to the "ON" position. (option) 7-3. Insert the key into the Starter Switch and turn itto the "RUN" position. Check to see that the Oil Pressure Light and Charging Light turn on. Itthey don't light, check the lubrication oil system, engine electric system for defective wiring.| 7-4. Tum the key to the "START" position to start the engine. Afier starting, remove the hand from the key immediately. Then the key retums to "RUN" Position. # When the engine will not start well in cold season: Tum the key to "HEAT" position. The Pre-heat Lamp will tun on for about 5 second. When the Pre-heat Lamp goes off, Turn the key to "START" position to start the engine. 7-5 Ifthe engine does not start within 10 seconds after the key is tumed to the "START" position, wait for about 30 seconds and repeat the procedure as described in step 7-4 above. 7-6 When the engine starts, the Oil Pressure Light and Charging Light should go out. Ifthe light stays on, immediately stop the engine and check the lubrication oil system, engine electric system and/or lights. (refer to the engine instruction manual for engine electric system), 7-7 Letthe engine idle for five minutes to warm-up 7-8 Check the engine for abnormal vibration, noise and oil leakage. 7-9 Regulate the output voltage by adjusting the voltage Regulator and set the engine speed by the Throttle Handle according to the load. - How to set the Throttle Handle- (1) Release the locked handle by turning the bottom of the Throttle Handle unclockwise (RELEASE). 2) Depressing the center button on the Throttle Handle, pull the Throttle Handle out slowly and fully to increase the engine speed. 3) Fine speed contro! will be done by adjusting the Throttle Handle, (turn it clockwise to decrease the engine speed and unclockwise to increase it) (4) Lock the Throttle Handle by turning the bottom of the Throttle Handle clockwise (HOLD) after setting the engine speed at rated speed. (5) For idling of the engine, release the locked Throttle Handle and push it down slowly depressing the center button. 7-10 Setthe circuit breaker to the "ON" position to supply electricity to the load.j | | | 10. STOPPING THE ENGINE 81 8-2 8-3 8-4 ‘Tum the load side circuit breaker to the "OFF" position, Tum the circuit breaker on the generating set to the "OFF" posi Let the engine run for five minutes to cool-down with the Throttle Handle pushed- down position. (idling operation) ‘Tum the key to the "STOP" position and remove the key. CAUTION WHILE OPERATION 9-1 9-2 9-3 9-5 ‘Never tum the Battery Switch to the "OFF" position during the operation (option). Check to see the Ammeter and keep the total amperage of the load within the rated amperage of the generating set, When the circuit breaker trips, check the possible causes and turn it to the "OFF" position once and then tum itto the "ON" position to reset. Always operate the generating set with the doors inthe closed position. Operation with the doors open may result in insufficient cooling and damage may result. Ifany abnormal noise, smoke, vibration and smell are perdeived, stop the engine immediately and check for the possible causes. EARTH LEAKAGE RELAY (OPTION) 10-1 Earth Leakage Relay The machine is equipped with an earth leakage Relay which detects leakage and breaks the circuit o prevent electrical shock during the operation. But misuse of this Relay may be much dangerous. Be sure to read carefully this instruction before operating the machine. The standard current sensivility of this breaker is 30mA. 10Earth Terminal (Ground terminal for leakage Relay) on II Earth Bar Note : For more safe operation, we recommend the installation of an earth lekage Relay on the circuit of the load (closer to the each load). 10-2 Operation Be sure to observe the following instructions to ensure safe operation of the earth leakage breaker. In case the earth relay actuates, stop the engine and check the possible causes and repair it. (1) _ Barthing on the generator side Earth the machine by connecting the attached earth pin to the earth terminal (ground terminal for leakage breaker installed on the control panel. (without this earthing, the earth leakage breaker may not function) Also earth the bonnet of the machine. Terminal (ground for bonnet) is installed on the rear panel. (2) Earthing on the load side Earth the bonnet of the box of the load, Note : The provision of earth lekage breaker on the machine can not climate the necessity for earthing the load. The load must be earthed to allow earliest possible detection of leakage. 11. MAJOR COMPONENT FUNCTION 11-1 A.C. Voltmeter This meter indicates phase to phase voltage of the three phase output terminals. il11-2. Frequency Meter This meter indicates the output frequency of the generating set. 11-3 A.C. Ammeter ‘This meter indicates curent flow to the load connected to the "U" phase wire. 11-4 Hourmeter ‘Thismeter indicates the operating time ofthe generating set 11-5 Circuit Breaker This circuit breaker connects or disconnects generator output from the three phase output terminals. Italso protects the generating set from short circuits oroverloads. 11-6 Voltage Regulator The voltage regulator allows manual adjustment of the generator output voltage, 11-7. Emergency Shutdown System This generating set is provided with safety devices to automatically stop the engine in the event below + lowoil pressure ~ abnormally high water temperature - _insufficent charge ‘This system furnished engine protection during operation. 12. INSPECTION AND MAINTENANCE At least daily or prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leakage. 12Inspection Procedure Ttem Procedure Period Check forthe fuel level and refuel aly fuel system | drain the fuel tank asnecessary clean the fuel filter every 100-200 hrs, replace the fuel filter every 400 hrs. check forthe ol level and refill it caily oil system | drainthe engine crankcase and refill oil seeengine manual replace the oil strainer see engine manual cooling check for water level and refill caily water clean fuel system components every 400-500 hrs air clean air cleaner element every 100-200 hrs cleaner replaceiit seeengine manual electric check for battery electrolyte level every 50 hrs. or system and replenish it oncea month, engine seeangine manual others clean the radiator fins asnecessaty check fan belt tension see engine manual 13. STORAGE (ay 2) 8) @) 6) For longterm storage of the generating set, the following procedures are required: Drain water from the radiator completely Drain the fuel tank completely Drain the oil from the engine crankcase completely and refill with fresh and clean oil Remove the battery and keep it charged Please refer to the engine maintenance manual. 1314. TROUBLESHOOTING Engine fails to start CHECH POINT NO Starter rotates , @, O, ©, O. Engine failstostat | ©, ©, ©, ©. Something wrong withengine |___— ©, @, ®, 9, ®. Insufficient outputofengine | © ,@® Engine suddenly stops during operation |~ ©,©,9,©,©,@,0,0,8,8 CHECK POINT No. fuel. Fuel strainer is closed Fuel pipe clogged or sucks in air ‘Water in fuel tank and in fuel system Cogged fuel strainer Battery switch turned "OFF" (option) Battery cable disconnected Inspect the battery electrolyte level and voltage Check oil level Use an oil with appropriate viscosi Clogged air cleaner Circuit breaker is turned "OFF" Generating set is over-loaded pecially in cold ambient temperature ‘No water in the radiator or the water level is too low Fan belt is loosened or broken Generating set operates in enclosed or confined area where the free flow of cooling airis restricted. eeeeseoes0e9e0008680 14battery switch in “OFF” positon option) —>twmnit “ON fective battery switch faption) — —prepiace Starter fais _ [discharged battery (option) > change o replace [7 to rotate —f- defective starter switch replace defective starter replace broken leads repair Engine fas tstat broken preheat cireuit repair 7 0 fuel S refuel "rotates Farin fel system repair o bled others see engine manual Engin compression leakage Hepsi engine Staring Engine remains_[- si in fuel system props o:beed at low speed “F copge fuel stisver Salen logged ai leaner ean [malfunction of replace exciting circuit [istetive rectifier (Re) —> replace Generator fais [broken amature winding —> replace to generate —fbroken fit winding — replace Engi defective rotor replace stats L broken leads P epair Cdofetive AVA, epee [rdefective AVA replace Voltage too [short in armature winding —> replace low —1-éefoctive rotor F replace engine sped is too low > raise engine speed to rating {detective voltage regulator—>replace Croltageisadustod wronghy—> ads it to rating “Engine speed—t-Vottage 100 _¢— defective AVA prepa tae Then" eto ated wren datectve engine aternator—>yroplace Batery detective ene reglter —>replce discharge — voken ass Srepar ‘eon Aefecive sater switch “preplace defective battery prepace Circuit beaker p—defectve beaker —propace trestle str cratinled ra vera rece th ad gine seams broken leads rep Weaied —C damaged boning prelce Ainomal ise engine se rep altenatr + damaged bearing replace site Linas laning tighten tals bonnet side ~yrepie 153009 YOIOD ONIN. area p amprgemeuy | yx wopeu | 61 wowneuy | oy 'SWYN Siuvd 10BWAS| 15.1 Generator Wiring Diagram (200V Class) ELR. 15. GENERATOR WIRING DIAGRAM 1615.2 Generator Wiring Diagram (200V Class) 3009 YO7I09 ONIN. 308 “xno s 4 ¥ A moape | 599 aapgemeny | a9 moped | 8 regamewy | ay ‘BAIN Siuva 1OBNIAS| 1715.3 Generator Wiring Diagram (400V Class)ELR @) ‘BWIVN Siuva 108NAS|'3d09 YO10D ONAN apa oe sap jammy | ave ope | 6 woemeuy | ay BMIVN Siva 10BWIAS| 15.4 Generator Wiring Diagram (400V Class)wouuas wauavas 3009 WOIOD ONIN og L000 ome AOI fe 20 = = x 3 a A g 6 & S a a 9 Zz a s17. OUTLINE DRAWING18. SAFETY PRECAUTION FOR DIESEL GENERATAING SETS AND EQUIPMENT To be read attentively before installing, operating or repairing the unit. ~ __Inaddition to general safety rules which should be observed with diesel generating setsand equipment, the following safety directions and precautions are of special importance. - When operating this unit, the operators expected to employ safe working practices and to observe al related local work safety requirements and ordinances. - Theowneris responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation. + Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent personnel. ~~ Ifany statementin this book, especially with regard to safety, does not comply with local legislation may not apply to the unit (s) described in this book. A. INSTALLATION Apart from general engineering practices that conform with the local safety regulations, the following directives are especially stressed: 1. Engine exhaust contains noxious elements Therefore, pay close attention to ventilation when operating the generator set inside tunnels, building, or other enclosed areas. 2. For outdoor operation, install the generator set that the exhaust is not discharged in the direction of nearby homes or other enclosed areas. 3. When the generator set is installed in a dusty or corrosive atmosphere, frequently inspect it for radiator clogging and other abnormal conditions 4. Provide adequate space for engine inspection, lubrication, refueling, cable connection to the load, and operation 5. Never remove or tamper with the safety devices, guards or insulations fitted on the unit 6. Besure thatthe generating set is on secure and level ground 22OPERATION 10. Select cables of proper thickness while referring to the load capacity and distance to the load. Then, securely connect them, Do not use any cable whose cover is broken and degraded. In connecting the cable, be sure to shut down the operation. Cover or tape the connections to prevent leakage and direct contact with the human body. Always check voltmeter and frequency meter indicates the rated, ammeter indicates under the rated current. All canopy doors should be shut during operation. People staying environments or rooms where the sound pressure level reaches or exceeds 90 db (A) shall wear ear protectors. The following items should be checked before start up: ) All guards should be in place and securely fastened. b) Water, engine oil or fuel leakage ©) Thatall fasteners are tight 4) Thatall electrical leads are secure and in good order ©) Oilleveland cleanliness 1) Cooling-water level (radiator and overflow tank) and radiator cap securely tightened ® Frellevel h) Tension ofall V-belts Provide a switch between the generator and load to operate or stop the load Always keep battery switch tumed "ON" while operating the engine. Also, always keep it "OFF" when engine is not running, (option) Do not wire the generator set to the interior circuit. Avoid low-load operation for long periods of time. Coolant: Use clean water when the temperature drops to (32°F) or below, the following mesures must be taken: a) Useantifreeze b) — Whenantifieeze is not used, Open drain cock of the engine and radiator to completely drain off cooling ‘water afier engine operation. 23uM. 12, 13. 14, 15, Fill the fuel tank frequently Periodically open the drain plug to drain moisture and contaminants. Avoid high speed operation immediately after starting, Never tum the starter switch to "Start" position while the engine is running Never stop the engine suddenly except in an emergency ‘Never touch any rotating, hot and live parts during operation. . MAINTENANCE Maintenance and repair work shall only be carried out under supervision of someone qualified for the job Use only the correct tools for maintenance and repair work. Use only genuine spare parts. All maintenance work, other than routine attention, shall only be undertaken. ‘when the unit is stopped. Never use flammable solvents or carbon tetrachloride for cleaning parts. ‘Take safety precaution against toxic vapours of cleaning liquids. Scrupulously observe cleanliness during maintenance and repait. Keep dirt away by covering the parts and exposed openings witha clean cloth, paper or tape. Make sure that no tools, loose parts or rags are left in or on the unit, Protect the electrical and regulating components, etc. to prevent moisture from entering these parts, e.g, when steamcleaning. All responsibility for any damage or injiury resulting from neglecting these precautions or by non-observance of ordinary caution and due care required in handling, operating, maintenance or repair, even if not expressly mentioned in this book, will be disclaimed by Denyo Asia Pte. Ltd. 24