Denyo DCA-800SPK User manual

m o m l o i
111П1 l l l i l l i
FOR
DIESEL ENGINE-DRIVEN
AC GENERATING SET
MODEL : DCA-800SPK
По вопросам продаж и поддержки обращайтесь:
Эл. почта: [e-mail] || Сайт: https://denyo.nt-rt.ru/
Архангельск [phone]
Астана [phone]
Астрахань [phone]
Барнаул [phone]
Белгород [phone]
Брянск [phone]
Владивосток [phone]
Волгоград [phone]
Вологда [phone]
Воронеж [phone]
Екатеринбург [phone]
Иваново [phone]
Ижевск [phone]
Иркутск [phone]
Киргизия [phone]-47
Казань [phone]
Калининград [phone]
Калуга [phone]
Кемерово [phone]
Киров [phone]
Краснодар [phone]
Красноярск [phone]
Курск [phone]
Липецк [phone]
Магнитогорск [phone]
Москва [phone]
Мурманск [phone]
Набережные Челны [phone]
Нижний Новгород [phone]
Казахстан (772)734-952-31
Новокузнецк [phone]
Новосибирск [phone]
Омск [phone]
Орел [phone]
Оренбург [phone]
Пенза [phone]
Пермь [phone]
Ростов-на-Дону [phone]
Рязань [phone]
Самара [phone]
Санкт-Петербург [phone]
Саратов [phone]
Севастополь [phone]
Симферополь [phone]
Таджикистан [phone]-69
Смоленск [phone]
Сочи [phone]
Ставрополь [phone]
Сургут [phone]
Тверь [phone]
Томск [phone]
Тула [phone]
Тюмень [phone]
Ульяновск [phone]
Уфа [phone]
Хабаровск [phone]
Челябинск [phone]
Череповец [phone]
Ярославль [phone]

This instruction Manual gives a detailed description of the
operation, routine inspection, maintenance, and troubleshooting
of the generator, and other items required for proper operation.
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 ’’ngine Instruction Manual” supplied
by the engine manufacture.
CONT NTS
1. PR CAUTIONS FOR SAF OP RATION ............. 1
2. SP CIFICATIONS 5
3. PARTS D SIGNATION ........................... - ............. 8
4. PR PARATION FOR OP RATION ............................... 15
5. OP RATION .................................................... 22
6. PARALL L OP RATION ....................................... 26
7. STORAG ....................................................... 28
8. INSP CTION AND MAINT NANC — - 29
9. TROUBL SHOOTING ............................................ 30
10. OUTLIN DRAWING ............................................ 31
11. CONTROL AND OP RATING PAN L ........................... 32
12. G N RATOR CONN CTION DIAGRAM ......................... 33
13. S QU NC DIAGRAM ......................................... 34
14. NGIN CONN CTION DIAGRAM .............................. 35
15. SAF TY PR CAUTIONS FOR DI S L G N RATING
S TS AND QUIPM NT ....................................... 36
- 1 -

1 . PR CAUTIONS FOR SAF OP RATION
This machine is designed with highest consideration to safety.
Safest and most efficient operation, however, can be attained
by paying attention to the following items.
(1) Operate Properly
Operate the machine properly according to the Instruction
Manual to ensure- safety.
Give proper guidance in operation
In allowing other personnel to use the machine, be sure
to give them proper guidance in its operation and advise
them to read the ’’Instruction Manual” before actually
operating it.
(2) Keep Free From Moisture
The operation of the machine in a place exposed to rain,
moisture or wetness may cause electrocution. For opera
tion under such conditions, be sure to ground the machine
and the load side.
(3) Housekeeping, The First Step
Do not place any unnecessary items around the machine.
When the machine is to be located on an uneven or soft
surface, install it horizontally so that it will not
tilt during operation.
(4) Clean Carefully And Frequently
The machine must be treated properly as your business
partner. Note that the insulation of the generator may
deteriorate depending on the place where it is used. If
it is to be used in a place where dust and moisture are
excessive, be sure to clean and dry it periodically.
- 2 -

(5) Pay Attention To Sufficient Ventilation
The exhaust gas discharged from the machine contains
hazardous substances. When the machine is to be used
in such a place as a tunnel, ventilate the place thor
oughly during operation. When it is to be operated on
the road, take care that the exhaust is away from pedes
trians, nearby buildings, etc.
(6) Shut Down Operation Immediately If Any Abnormality Occurs
If the machine is found to operate improperly, or produce
any abnormal odor, noise, or vibration, immediately shut
down the operation for troubleshooting to correct the ab
normal i ty.
(7) Maintain lectrical Instrument Cables Properly
Damaged cables of the electrical instruments are very
dangerous, causing electrocution and leakage. Therefore,
if such a cable is found, immediately repair or replace it.
(8) Avoid Overloading
The generator is provided with a breaker
for overload protection, which is
breaker has been actuated, reduce the
load before restarting the machine.
(9) Never Touch The Output Terminal
Never touch the output terminal during the operation.
Be sure to shut down the operation before touching the
terminal for wiring, etc.
(10) Pay Attention To Storage And Transportation
During Inclement Weather
actuated when it is overloaded. When the
The machine is designed for dripproofing,
but not for rainproofing. When it is to be
stored or transported on an inclement day,
take care to cover it.
- 3 -

(11) Wash The Machine Carefully
Wash the machine taking care that the control panel and
the inlet and outlet ports are not exposed to water to
prevent possible failure of the internal instruments.
(12) Take Precautions Against Fire
Handle fuel, oils and antifreeze (undiluted) with care
because they are dangerous materials with high flammabili-
ty. Do not bring any naked light such as lit tobacco or a
burning match close to them. In addition, do not install
and store the machine in a place near where fire is used.
(13) Connect Securely
Damaged cables and loosened screws result in machine failu
re and electrocu-tion. Therefore, immediately repair such
cables and tighten such screws securely, if any.
(14) Perform Inspection And Maintenance Work Perfectly
Keep the machine clean and its inside
free from dust and moisture. In addition,
perform its inspection and maintenance
perfectly in accordance with the ’’Inst
ruction Manual”.
- 4 -

2 . SP CIFICATION
2-1 AC Generator
Generator model
Type
xcitation
Continuous duty rating
Vo 1 tage
Current
Frequency
Speed
Power factor
Phase
Winding connection
Insulation
Cooling system
2-2 Diesel ngine
Maker and model
Rated output
No.of cylinders
Bore X Stroke
D isp 1 acement
Direction of rotation
Governor
Coo ling system
Lubricating system
Starting motor
Charging generator
Battery
Fuel
Fuel tank
Lubr i cat i ng oil
DF-8800
Rotating-field,protection type(JP20)
synchronous generator
Brushless type (with AVR)
700 / 800 KVA
200 / 220 V or (380) {415) 400 / 440 V
2021 / 2100 A or (1063){974)1010 / 1050 A
50 / 60 Hz
1500 / 1800 rpm
0.8 (lagging)
3 (4 wires)
Star
Armature-winding -- F class
Field-winding -- F class
Se 1 f-vent i1 at i on
KOMATSU LTD. SA 12V 140
4 cycle.water cooled diesel engine,direct
injection,turbocharged with aftercooler.
834 / 1000 ps. 1500 / 1800 rpm
12
140mm X 165mm
30480 cc
Clockwise (viewed from the fan side)
lectronic governor
Water cooling by radiator with fan
Gear pump
24 V - 7.5 kW X 2
24 V - 25 A
12 V - 2 0 0 A H X 4
Diesel fuel (JIS No.2 or equivalent)
Approx. 490 1
API service class (CD class or higher)
-5 -

3. PARTS D SIGNATION
3-1. Description of Devices
(1) Starter Switch
OFF/STOP
Ф STOP
Keep the switch at this position except
during operation.
This position allows the key to be inserted
into and removed from the switch.
Keep the switch standing at this position
during operation.
® START
Turn the switch to this position for start
up. When the key is released after startup,
it automatically returns to “RUN” position.
© For startup at low air temperature,set the switch at this position
until the “ PR H AT ” lamp becomes red-heated just before turning
the key to “ START ’’position.
(2) Tachometer
The tachometer indicates engine revolu
tions per minute. Set the engine speed so
that the meter indicates 1500rpm at 50Hz
and 1800rpm at 60Hz. The tachometer has
a builtin integrating hour meter.
The integrating hour meter has been set for use at 1500rpm.
Accordingly, when the meter is used at 1800rpm, it indicates
an integrated hour value approximately 20% more than the
actual operation time.
- 6 -

(3) Cooling Water Temperature Gauge
If machine is in normal operation, the in
dicator should between 75 - 95 °C . If it
indicates temperature above this range,
turn off the load and turn the speed-change
over switch to ’’L O W ” position for cold operat
ion to reduce the cooling water temperature.
(4) Lubricating Oil Pressure Gauge
If the machine is in normal operation,
the pressure gauge indicates 3~5 kg/cnf.
When the engine is cold, the pressure may
rise aboye this range just after startup.
In such cases, perform warming-up until
the normal pressure is attained.
(5) Lubricating Oil Temperature Gauge
Indicates the oil temperature of the engine oi
The temperature of 100 °C or less is recommen
ded.
(6) Fuel Level Gauge
rs ' . ■ ’ f 4
■ B*
,и»Ч
. i
fU ffc W
Indicates the fuel level in the fuel tank,
(7) Charging Ampere Meter
If the machine is normal operation, the
meter points to 0 or + range values (ind
icating its changed state ).
- 7 -

(8) Preheat Lamp
This lamp,when the key switch is turned to
“PR H AT” position,goes red-heated in about
30 seconds, indicating that the machine has
been preheated.
(9) Dust Indicator
Reset button
Red piston
When the air cleaner element is clogged,the
dust indicator’ s red piston sticks out of its
transparent portion.
In such cases,immediate 1 у replace or clean the
e 1 ement.After replacement or с Ieaning,press the
indicater button to return the red piston to
its original position.
(10) Throttle Lever
144
IUK Q I lt-E. L m K
i,i imH
O
Turn the handle toward the ’’HIGH” side to
increase the speed and toward the ’’L O W ”
side to decrease it.
(11) Battery Switch
During operation, never turn the switch to
’’O F F ” position, keeping it at ”o n ”.
If the engine is shut down, be sure to
place the switch in "OFF” position.
OFF ON

Ш - S T A R T
aibT'f v'jy?
AUTO. IDLING
(12) Speed Changeover Switch
® AUTO. IDLING
When the engine is started with the ’’SP D”
changeover switch set at this position, the
engine idles for about 20 seconds and then
automatically changes over to high-speed
operation. When starting the engine, set the
sw i tch in this position.
© LOW
When the switch is turned to this posi
tion, the engine continues to idle.
© HIGH
Turning the switch to this position relea
ses the ”automatic idling” function, allowing
the engine to be run at the speed set by the
thrott le handle.
(13) Running Caution Lamp
This lamp goes on during low-speed operation.
(14) mergency Stop Button
This is a pushbutton to stop the engine urgently on emergency
case.
Do not push the button without emergency case.
(15) Oil Filter Alarm Lamp
This lamp will go on when the oil filter is blinded.If the lamp
lights up,replace the filter element immediately.
(16) OK Monitor
This monitor indicates the following failures, if any one of them
occurs. □G2
- 9 -

© Overheat
This lamp goes on when the cooling water
temperature rises abnormally. If the lamp
goes on during operation, the emergency
stop device immediately operates to-shut
down the engine automatically.
*2».
Oi 1 Pressure Failure
If the machine is in normal operation,
this lamp stays off. When the starter
switch is turned to ’’R U N ” position to
start the engine, the lamp goes on, and
when the oil pressure rises after startup,
it goes off. If this lamp goes on during
operation ,the emergency stop device imme
diately operates to shut down the engine automatically.
After the engine stops, the lamp stays on unless the starter
switch is turned to ’’S T O P ” position.
® Fuel Leve 1 Failure
When fuel is running low, this lamp goes
И on, and the tank should be filled.
© Battery Fluid Level Failure
When battery fluid runs low, this lamp
goes on, and distilled water should be
1ЖЭР supplied to the battery.
- 10 -

(17) Frequency Meter
(18) AC Ammeter
This meter indicates the power frequency.
Make sure that the meter pointer stands
at 50 or 60Hz during operation.
The ammeter indicates the value of curr
ent flowing in the load connected. Make
sure that the current value is below that
rated. Use the ammeter change-over switch
to check each phase for current Yalue.
(19) AC Voltmeter
The voltmeter indicates the output volt
age. Make sure that the voltmeter pointer
stands at the rated voltage. Use the
voltmeter change-over switch to check
each phase for voltage value.
... i' ' ■
\ V ' - o -
® 0 ®
(20) Voltage Regulator
This regulator is used to control the
output voltage. Turn the regulator
clockwise to increase the voltage and
counter-clockwise to decrease it.
Adjust the voltage to the rated voltage
with this regu 1 ator.
(21) Air Circuit Breaker
Refer to the item 3-2
- 11 -

(22) AC Wattmeter
Indicates output(kW) of the generator. Always
operate the generator at the rated output or less
The rated output is shown below:
50 Hz • • • • 560 kW
60 Hz .... 640 kW
Should the generator power be reversed during parallel operation,
the wattmeter will indicate negative values.
(23) Stator thermometer
Indicates the temperature of the generator
armature.
Measurement range : 30 *C to 110 *C
(24) Bearing thermometer
Indicates the temperature of the generator
bear i ng.
Measurement range : -20 'C to 60 °C
Note 1. Their thermometers display errors as below.
■ Error Displays
Temperature is below the thermometer’s measurable range.
FFF Temperature is above the thermometer’s measurable range.
Flashing — Temperature sensor’s lead wire has broken.
Flashing FFF Temperature sensor has short circuited.
Note 2. Their' s battery life is 10 years min.
Only battery cannot be changed. If the battery is dis
charged , change a complete set(disp1 ay,sensor and leadline)
- 12 -

(25) Overcurrent Relay
a) ach set value for the overcurrent relay factory-adjusted with
the performance of the generator. Do not modify any set values.
b) When the relay is actuated,the indicator(orange)is lit on to
display the cause of such actuation. Display of tripping indi
cates the phase at which the trouble current was largest. Should
the indicator display “instantaneous” .there is a large possi
bility of short circuit. In any case, check the cause.
Display of the indicator Indicator
Troubles Tr i p p i ng Instant
aneous
Phase R Phase T
Over
load
Between R and S (U-V) •——
Between S and T (V-*) —•—
Between T and R (W-U) •
(IR>IT) •
(IT>IR)
—
Between R.S and T(U-Y-ff) —
Short
с i rcu i t
Between R and S (U-V) •—•
Between S and T (V-tf) —• •
Between T and R (If-U) •
(IR>IT) •
(IT>IR) • Between R,S and T(U-V-W) •
Note: IR=current in phase.R. IT=current in phase T.
c) A set of five L D’s provided on the surface of the relay will
indicate the operating conditions of the relay.
3-2 HANDLING TH AIR CIRCUIT BR AK R
® Circuit breaker ON button
® Circuit breaker OFF button
® Circuit breaker ON lamp
© Circuit breaker OFF lamp
( lectromagnetic operation)
1) С1 osing
The circuit breaker is closed by pressing the push button switch
“ON” on the control panel,and the circuit breaker ON lamp is lit.
- 13 -

2) Opening
The circuit breaker is opened by pressing the push button switch •
“OFF” on the control'panel,and the circuit breaker OFF lamp is lit
(Manual operation)
The air circuit breaker may be manually operated. However,limited
the manual operation to maintenance and inspection prosedures and
to emergency where it cannot be e1ectromagnetica11 у operated.
The air circuit breaker is located on the right side of the control
box. First,remove the protective cover from the control box.
•
W - i i
Ш
gzz
:o J •
Charging handle
Front panel of breaker
Ф Charging handle
© OP N-CLOS D indicator
® Spring charged indicator
© PUSH TO CLOS button
© PUSH TO OP N button
© Open position padlock lever
© Charging motor power switch
1) Spring charging operation
Pump the charging handle. When the closing springs are fully
charged,a metallic “click” will be heard and no further pumping
of the charging handle of the charging handle will be possible.
When the charging handle is pumped with its maximum stroke,about
four pumping cycles will complete the charging. Check that the
spring charged indicator shows “CHARG D” .
2) Closing operation
Open the clear shutter upward and press the PUSH TO CLOS button.
This release the charged closing springs and the breaker is closed
The OP N-CLOS D indicator shows “CLOS D” ,and the spring charged
indicator shows “DISCHARG D”
3) Opening operation
Open the clear shutter upward and press the PUSH TO OP N button.
This trips open the breaker,and the OP N-CLOS D indicator shows
“OP N” .
- 14 -

4. PR PARATION FOR OP RATION
4-1. Precautions In Installation
Install the machine horizontally on solid ground,
in addition, when the machine is to be installed in a place
where dust and salt are excessive, pay close attention to
its maintenance and care to prevent radiator clogging and
failure, and electrical-part insulation failure possibly
caused by operation under such circumstances.
(1) Precautions In Outdoor Installation
When the machine is to be install outdoors such as on the
road, pay attention to the wind direction and the exhaust
port position so that the exhaust gas it away from pedest
rians and nearby' bu i ldings.
(2) Precautions In Indoor Installation
Ф Leave enough space for easy operation and control on the
contrо 1-pane 1 side ( at least 1 m )
© Leave enough space for engine inspection, lubrication,
connection of cable to the load, fuel supply and other
operations both on the right and left sides viewd from
the control panel (at least 1 m ).
® Install an exhaust pipe so that exhaust gas is discharged
through it to an open area.
® Leave enough space for exhaust of warm air discharged
through the radiator, supply of water to the radiator,
and arrangement of the exhaust pipe above the machine.
© Note that the connection of the generator to indoor
wiring not only infringe the law, but also may cause
electrocution or generator failure.
© Note that the machine can be installed directly on a found
ation such as concrete.
© Install the machine in such a place as can be thoroughly
ventilated to prevent a considerable rise in the indoor
temperature, which has an adverse effect on the engine
generator.
- 15 -

4-2. Check Before Startup
Be sure to check the Machine especially for the follwing
points before startup to minimize machine failure.
(1) Check Oil
ж Be sure to check the oil level before startup every day.
rll
L m
L
О
Good Too high Too low
Note : Some engine manufactures provide a level gauge with
such 11/L marks on both sides, which allows the oil
level to be checked during idling. When using such
a level gauge, carefully check which of the two H/L
marks is used at downtime or during idling,
ж Check engine oil with an oil level gauge to see that the
oil level is in between marks H and L of the level gauge,
and replenish or replace it if necessary,
ж For oil replenishment, supply a given amount of oil from
the oiling port provided on the engine.
ж After a specified amount of oil engine is supplied, run
the engine for several minutes and then stop it to check
again to see that the oil level stands in between marks
H and L of a level gauge.
Notes : For specified quantity of lubricating oil,refer
to the Specifications Table.
(2) Check Cooling Water
Put water
to ’’F U L L ”
- 16 -

In checking or supplying cooling water, make sure that the
engine is cold. For cooling water in winter, refer to the
’’n g i n e Instruction Manual”.
Use tap water as cooling water and put it up to the root of
the filling port, some machines are provided with a reserve
tank, put tap water in it up to the ’’F U L L ” mark.
In setting the radiator cap after the cooling water check
or supply, take.care to turn it clockwise to full position
so that the radiator can be used with its inside kept in a
pressurized state. Insecurely-tightend radiator cap may
result in serious engine trouble.
Notes : For specified quantity of cooling water, refer to
the Specifications Table.
(3) Check Fan Belt
Check the belt for tention and elongation. Adjust them if
necessary. If any abnormality is found on the belt, re
place it. Perform the adjustment and replacement as dire
cted in ’’ngine Instruction Manual”.
The belt tention is considered to be
proper if the flexing level is within
10-15 mm when the arrow-indicated portion
(belt center) is pressed with the thumb
(approximately 6kg).
(4) Check Fuel
Be sure to check the fuel level before startup to prevent
fuel shortage during operation. Occasionally remove sedi
ment and contaminated water collected in the bottom of the
fuel tank by loosening its drain plug.
Frequency 50Hz 6011z
Fuel Consumption(1/hr) 138 165
- 17 -

(5) Check Generator Case Grounding
When the generator is installed in a moist place, or on
highly conductive material such as iron plates or steel
work, be sure to connect the grounding wire terminal
provided near the output terminal block and bury the wire
50 cm or deeper in the ground securely.
Do not directly ground terminal ”0 ”.
Recomended grounding wire sectional area: 5.5 ш nf or larger
(6) Check For Water And Oil Leakage
Check the engine periphery for water and oil leakage. If
such leakage is found, identify the leak spot and repair it
(7) Check Bolts And Nuts For Looseness
Check bolts and nuts, especially on the air cleaner,
muffler and turbo-charger mounting portion, for looseness
and tighten them if necessary.
(8) Check lectrical Wiring For Disconnection, Short And Ter
minal Looseness.
50cm or more
Grounding wire
Case grounding terminal
18 -

4-3. Load Connection
In connecting a load, tighten locking bolts securely with
a spanner, etc. to prevent burning.
(1) Three-phase Output
Use U/V/ff for three-phase load
200/220V or 400/440V
(380V)
{415V}
U V W
V V V
Use 0/U,0/V,0/W for single-phase load
115/127V or 231/254V
(220V)
{240V}
Use U/V,V/ff,W/U for single-phase load
200/220V or 400/440V
(380V)
{415V}
- 19 -