DCA70SSJU4i
19.6 kW Load Bank Installation
The following instructions are intended to assist the user in the installation of the 19.6 kW Load Bank for use on the
DCA70SSJU4i generators. Please read all assembly instructions before installing load bank.
REQUIRED TOOLS
2. Place the generator in an area free of dirt and debris.
Make sure it is on secure level ground with chock blocks
„„Ratchet Set
„„Power Drill
underneath each wheel to prevent the generator from
rolling.
„„Flat/Phillips Screwdrivers „„2-Inch Chassis Punch
„„Wire Cutters
3. Disconnect negative battery cable from the battery.
PARTS
Verify that all parts are accounted for. See Figure 1 and
Table 1.
1
2C
10
11
2D
2B
9
2
8
2D
2A
4
3
Table 1. Power Balance Kit
Item No.
Part No.
Description
QTY.
Remarks
1
MQPPB70J4I
KIT, POWER BALANCE, 19kW
1
Includes Items
2-6,8,10,12-18, 29
2
70SSJU4IPBSKIT
Kit,Sheet Metal,Power Balance
1
Includes Items
2A-2D
2A
EE58360
Angle, Contactor Box Support
1
2B
EE58359
Bracket, Contactor Box,14x16"
1
2C
EE58361
Cover, Roof,19 kW Resistor
1
2D
EE58362
Cover Plate, 2-Row Resistor
2
3
EE58673
2" Rubber Grommet
1
4
EE58325
Resistor Assy. 19 kW
1
5
EE58364
Contactor Assy. 19 kW
1
6
EE58365
Load Bank Wire Harness, 10 AWG.
1
7 Wires
Load Bank Split Loom, 3/4" X 126"
126"
Obtain Locally
Power Wires (UVW-GND), 8 AWG.
1
4 Wires
UVW-GND Split Loom, 3/4" X 40"
40"
Obtain Locally
DC Control Wires, 16 AWG.
1
6 Wires
DC Control Split, Loom, 3/8" X 54"
54"
Obtain Locally
7
R1
R2
R3
R4
A1
R12
6
R5
A2
R11
R6
A3
A10
R9
HARDWARE
8
27
10
26
A4
A12
A5
R8
A11
A6
R7
A10
A9
A8
A7
7
14
5
ECU
28
Series 800 Controller
Engine Started
Shutdown
16
Pre-Alarm
Screen
Alarm
Acknowledge Change
12
Option
13
29
INSTRUC
TIONS
Program/
Exit
19
20
17
21
9
EE58517
11
15
PATENT PENDING
EE58515
24
12
EE58370
Tailpipe Extension, 3" Dia. X 13" SS
1
13
EE16745
Clamp,U-Style, 3" Zinc
1
14
EE57143
Decal Power Balance, 5.4” X 1.5”
1
15
EE57145
Decal Patent Pending, 2.70” X 0.55”
1
16
ECU835
ECU Module
1
Fuse, 10 AMP (AGC10)
1
Obtain Locally
Fuse Holder, In-Line, 10 AMP
1
Includes Item 17
19
3/8" X 20 Bolt
1
Obtain Locally
17
18
23
25
22
Figure 1. Power Balance Kit (DCA70SSJU4i)
WORK SAFELY!
Only a qualified service technician with proper training
should perform this installation. Follow all shop safety rules
when performing this installation.
PREPARATION
1. Make sure generator is turned off and engine is cool.
18
303110
20
3/8" Lock Washer
1
Obtain Locally
21
3/8" Flat Washer
1
Obtain Locally
22
G-Clamp 3/8-16"
1
Obtain Locally
23
Tie Wrap, #4
6
Obtain Locally
24
Tie Wrap, #6
10
Obtain Locally
25
Tie Wrap, #8
10
Obtain Locally
26
6mm X 15M Screw
21
Obtain Locally
27
6mm X 15M Lock Washer
21
Obtain Locally
28
6mm X 15M Flat Washer
21
Obtain Locally
Work Instructions, Power Balance
1
29
EE58627
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 1
FRONT PANEL REMOVAL (TOW SIDE)
TAIL PIPE
EXTENSION
1. Locate the generator front panel as shown in Figure 2.
2. Remove the 12 screws (Figure 2 ) that secure the front
panel to the cabinet housing.
U-CLAMP
MOUNTING
HARWARE
MUFFLER
EXHAUST
COVER
DISCARD
WHIS
FRONT
PANEL
PERW
ATT
CABINET
HOUSING
Figure 3. Tail Pipe Extension
3. Secure tail pipe extension with U-Clamp (P/N
EE16745).
GROMMET INSTALLATION
MOUNTING
HARWARE
1. Using a chassis punch or equivalent tool, cut a 2-inch
diameter hole into the front frame cabinet sheet metal
as shown in (Figure 4).
13.50”
Figure 2. Front Panel/Exhaust Cover Removal
3. Remove front panel, set aside where it will not get
damaged.
FRONT FRAME EXHAUST COVER REMOVAL
1. Remove the 10 screws that secure the exhaust cover
(Figure 2) to cabinet housing.
IA.
2.0” D
TING
EXIS OMMET
/GR
OLE
H
”
T
L/CU
DRIL HOLE
W
E
N
5.50
NT
FRO
OF
ON INET
I
T
EC CAB
E
KS
BAC FRAM
2. Retain mounting hardware.
3. Discard front frame exhaust cover.
MUFFLER TAIL PIPE EXTENSION INSTALLATION
1. Locate muffler tail pipe extension (P/N EE58370).
2. Place the flanged end over the existing muffler pipe
section as shown in Figure 3.
Figure 4. 2-Inch Diameter Hole Cut-Out
2. Remove any sharp edges from the hole opening.
3. Insert 2-inch diameter rubber grommet (P/N EE58673)
into hole opening.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 2
ANGLE BRACKET INSTALLATION P/N EE58360
1. Located underneath the voltage selector switch
J-box there should be an existing support angle
bracket (Figure 5).
COVER ROOF ASSY. P/N EE58361
VOLTAGE SELECTOR
SWITCH J-BOX
CONTACTOR
J-BOX ASSY.
P/N EE58364
SIDE B
EXISTING
ANGLE
BRACKET
SIDE A
EXISTING
SCREW
LOCK WASHER
R1
R2
R3
R4
A1
R12
R5
A2
R11
A10
A12
NEW ANGLE
BRACKET
P/N EE58360
NEW ANGLE
BRACKET
P/N EE58359
R6
A3
A4
R9
A5
R8
A11
A6
R7
A10
10 AWG 11”.0
RESISTOR LOAD BANK
P/N EE58325
A9
A8
A7
6MM SCREWS
WITH LOCK/FLAT
WASHERS 10 PLACES
10 AWG 11”.7
10 AWG 12”.5
10 AWG 12”.1
Figure 5. Mounting Brackets
10 AWG 12”.2
2. Remove the bottom screws (2) on the existing J-box
support angle bracket as shown in Figure 5.
3. Next, attach angle bracket (P/N EE58360) to the
existing J-box support angle bracket using the
hardware that was removed in step 2.
ANGLE BRACKET INSTALLATION P/N EE58359
10 AWG 12”
10 AWG 12”.6
GND.
T3
T2
T1
T3
CONTACTOR
K1
T2
T1
CONTACTOR
K2
CONTACTOR J-BOX P/N EE58359
Figure 6. Load Bank Connections
1. Using 6MM screw (6) with lock washers and flat
washers, attach angle bracket (P/N EE58359) onto
newly installed angle bracket (P/N EE58360).
2. Insert these seven wires into the 10.5" Load Bank
split-loom harness (P/N EE58635).
2. Tighten all screws securely.
3. Once the wires have been inserted into the load bank
split-loom harness secure using tie-wraps.
CONTACTOR J-BOX INSTALLATION P/N EE58364
4. Next, attach the six wires to the Resistor Load Bank as
referenced in Figure 6 and Table 2. Please reference
the labeling and length of each wire.
1. U s i n g 6 M M s c r ew ( 4 ) , i n s t a l l C o n t a c t o r
J-Box (P/N EE58364) (Figure 5) onto angle bracket
P/N EE58359.
RESISTOR LOAD BANK WIRING
There are seven BLACK 10 AWG wires that need to be
connected to Resistor Load Bank P/N (EE58325). Six of
the wires are to be connected to the 12 resistors located
inside the load bank, the remaining wire will be connected
to chassis ground.
Connect the 6 resistor load wires and ground wire as
follows:
1. Place the Resistor Load Bank with the Side-A facing
as shown in Figure 6.
Table 2. Resistor Load Bank Wiring
Resistor/GND.
Load Bank
Position
Wire Length (ft.)
Black 10 AWG
R1
A1
12.0
R3
A3
12.6
R5
A5
12.1
R7
A7
12.5
R9
A9
12.2
R11
A11
11.7
GND
GND Screw
11.0
5. To prevent arcing, tighten all nuts securely.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 3
R O O F C OV E R / R E S I S TO R L OA D BA N K
INSTALLATION
Use the procedure below to mount the Resistor Load Bank
(P/N EE58325) into the Roof Cover (P/N EE58361).
1. Lift the Resistor Load Bank (Figure 7) upward and
align mounting ear holes with flange bracket holes on
Roof Cover.
COVER ROOF ASSY.
P/N EE58361
SIDE B
SIDE A
2. Secure Resistor Load Bank to Roof Cover using three
6MM hex head screws. The fourth 6MM screw is for
the GND. wire.
COVER PLATE (2)
ASSY. P/N EE58362
6MM MOUNTING
SCREW (12)
WITH LOCK/FLAT
WASHERS
Figure 8. Cover Plate Mounting
5. Place and align the Roof Cover (P/N EE58361) on top
of cabinet housing as shown in Figure 9.
ROOF COVER
P/N EE58361
3
SIDE A
2
GND. WIRE
TERMINAL
RING
R1
R2
R3
R4
A1
R12
R5
A2
R11
A10
A12
4
R6
A3
A4
R9
A5
R8
A11
A6
R7
A10
A9
A8
A7
RESISTOR
LOAD BANK
P/N EE58325
ROO
F
P/N COVE
R
EE5
8361
MOUNTING
HARDWARE
1
Figure 7. Roof Cover/Resistor Load Bank
Installation
3. Connect the ground wire to the Resistor Load Bank as
referenced in (Figure 7).
CAB
INET
HOU
SING
4. Using 6MM screw (12) with lock washers and flat
washers (Figure 8), install Cover Plate (P/N EE58362)
onto A and B sides of Roof Cover (P/N EE58361).
Figure 9. Roof Cover Mounting
6. Use the mounting hardware removed in the "Front
Frame Exhaust Cover", step 2 to secure the Roof Cover
to the cabinet housing.
7. Tighten all screws securely.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 4
RESISTOR LOAD BANK WIRE HARNESS ROUTING
1. There should now be seven wires connected to the
Resistor Load Bank.
2. Route the load bank split-loom harness (Figure 10)
through the 2-inch rubber grommet on the front frame
cabinet.
CONTACTOR
J-BOX
OVERFLOW TANK
CONNECT TO
RESISTOR LOAD BANK
K1
K2
ES
6 WIRTORS
TAC
CON
CONNECTOR
BUSHING
A11
A5
A1
A7
A9
A3
T3 T2 T1
T3 T2 T1
K2
K1
RUBBER
GROMMET
GND
POIN .
T
FRONT FRAME
CABINET
SPLIT-LOOM
HARNESS
INSTALL
3/8” G-CLAMP
Figure 10. Load Bank Split-Loom
Harness Routing
3. Next, continue routing the split-loom harness through
the front cable connector bushing on the Contactor
J-Box.
4. Position the 6 load bank wires near contactors K1
and K2.
5. Position the BLACK ground wire (Figure 10) near the
Contactor J-Box ground point.
CONTACTOR J-BOX WIRING
There are two contactors (K1/K2) that require wiring via the
Resistor Load Bank. Connect the six wires to the contactors
as shown below:
Figure 11. Contactor Wiring
Table 3. Contactor J-Box Wiring
Load Bank Position
Contactor (K1/K2)
A1
K1-T1
A5
K1-T2
A9
K1-T3
A7
K2-T1
A11
K2-T2
A3
K2-T3
GND
GND Screw
1. Connect the six black wires coming from the Resistor
Load Bank to the K1 and K2 contactors as shown in
Table 3 and Figure 11. Tighen all wires to 40 in. lbs.
(4.52 N.m).
2. Attach the BLACK 10 AWG. ground wire to the
Contactor J-Box ground point. Tighten ground wire to
40 in. lbs. (4.52 N.m).
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 5
FUSE WIRE HARNESS ROUTING
There is a fuse block located inside the Contactor J-Box
that contains three 60 amp fuses (F1, F2 and F3). Position
load wires to the fuse block as follows:
1. Insert four 8 AWG. RED, BLACK, BLUE and GREEN
wires into the 40-inch fuse block split-loom harness
(EE58515) as shown in Figure 12.
2. Once the wires have been inserted into the split-loom
harness. Secure using tie-wraps.
3. Next, continue routing the split-loom harness through
the rear cable connector bushing on the Contactor
J-Box.
2. Tighten the nut securing the load wires to the fuse
block to 60 in. lbs. (6.78 N.m)
3. Connect the GREEN 10 AWG. ground wire to the
Contactor J-Box ground point as shown in Figure
12 and Table 4. Tighten ground wire nut to 40 in. lbs.
(4.52 N.m).
Table 4. Fuse Wiring Connections (UVW)
Wire Length (ft.)
Fuse
Color (Phase)
8 AWG
F1
BLUE (W)
4
F2
BLACK (V)
4
F3
RED (U)
4
4. Position the 3 fuse wires (Figure 12) near the fuse
block. If necessary, secure wiring with tie-wraps.
OUTPUT TERMINAL PANEL ENCLOSURE REMOVAL
5. Position the GREEN ground wire near the Contactor
J-Box ground point.
1. Remove the four screws as shown in Figure 13 that
secure the output terminal enclosure to the cabinet
frame.
OUTPUT TERMINAL
PANEL ENCLOSURE
REMOVE
SCREW
4 PLACES
CON
TAC
J-BO TOR
X
FUS
BLO E
CK
S
IRE K
3 WBLOC
E
S
FU
F1
F2
OUTPUT TERMINAL
PANEL REAR
O W
V
U
F3
GRE
BLUE
BLK
EN
RED
BLU
GRN.
GND.
POINT
ROUTE TO OUTPUT
TERMINAL PANEL
(REAR, UVW-GND)
E
BLK
8A
4 PL WG
ACE
S
CONNECTOR
BUSHING
FUSE BLOCK
SPLIT-LOOM
HARNESS
P/N EE58515
3/4, 48-INCH
SPLIT-LOOM
HARNESS
GND.
Figure 12. Fuse Connections
FUSE WIRE CONNECTIONS (UVW AND GND.)
1. Connect the three 8 AWG. RED, BLACK, BLUE
wires to the load side of the fuse block as shown
in Figure 12 and Table 4.
RED
TO FUSE
BLOCK
F1
F2
F3
Figure 13. Output Terminal Panel
Enclosure Removal
2. Lift and remove the enclosure from the output terminal
panel. Set the enclosure aside.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 6
OUTPUT TERMINAL PANEL (UVW-GND.) WIRE
CONNECTIONS
1. Connect the four 10 AWG wires RED, BLACK BLUE
and GREEN to the rear of the ouput terminal panel as
shown in Figure 13 and Table 5.
Table 5. UVW-GND Output Terminal Wiring
Function
Color
U
RED
V
BLACK
W
BLUE
1
N/A
O
GND.
GREEN
1
Terminals O and GND. are bonded
Color
BROWN
RED
RED
RED/WHT
GRN/WHT
YELLOW
Table 6. DC Control Wiring
Contactor J-Box
Destination
Terminal
TB1-1
ECU Pin-57
TB1-2
ECU Pin-16
TB1-2
VS Switch Pin-42
TB1-3
10 AMP Fuse
TB1-4
Ground (Ctrl. Bx.)
TB1-5
ECU Pin-13
CONTACTOR
J-BOX
6-WIRES
2. Once all four wires have been securely connected to
the rear of the output terminal panel, re-install output
terminal panel enclosure.
ALL WIRES
16 AWG.
1
1
2
2
3
3
4
4
4
4
4
4
5
5
DC CONTROL SPLIT LOOM HARNESS (CONTACTOR
J-BOX SIDE)
There are six wires, (P/N EE58517) that need to be
connected to the Contactor J-Box. Connect the wires as
shown below.
1. Insert the 6 wires into the 3/8", 54-inch DC Control
split-loom harness (P/N EE58517).
2. Once the wires have been inserted into the split-loom
harness secure using tie-wraps.
3. One side of this harness (Figure 14) has 6 wires with
the insulation stripped back 1/2-inch. The other side
has 3 terminal rings attached to the wires.
TO ECU,CTRL. BX.
VOLTAGE SEL. SW.
DC CONTROL
3/8” SPLIT-LOOM
HARNESS
P/N EE58517
TB1
1
2
3
4
4
4
5
BRN
1
RED
DC CONTROL
3/8” SPLIT-LOOM
HARNESS
P/N EE58517
2
3
4
4
4
5
YEL
RED/ GRN/
WHT WHT
TO ECU,CTRL. BX.
VOLTAGE SEL. SW.
Figure 15. DC Control Wiring (TB1)
TO CONTACTOR
J-BOX (TB1)
5 FT
Figure 14. DC Control Split Loom Harness
4. Route the split-loom harness through the front right
cable connector bushing on the Contactor J-Box. Be
sure to route only the stripped wires up to the J-Box
not the terminal ring side.
5. Connect the six wires to the Contactor J-Box as shown
in Figure 15 and Table 6.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 7
ECU 830 MODULE REMOVAL
NEW ECU 835 MODULE INSTALLATION
1. Loosen the two panel release knobs (Figure 16) that
secure the Control Panel to the cabinet frame.
1. Place the new ECU 835 module onto the Control Panel
Secure module using the hardware as referenced in
step 4 "ECU 830 Module Removal".
PANEL
RELEASE
KNOB
25
50
75
140
180
100
18
12
220
PSI
0
24
°F
VOLTS
100
260
6
30
DECREASE
INCREASE
OIL PRESS
WATER TEMP
BATTERY
½
120
150
180
60
RPMX10
E
F
FUEL
0
V
210
SPEED
U
W
OFF
ECU
V-W
Series 800 Controller
Engine Started
W-U
U-V
Shutdown
OFF
Pre-Alarm
Screen
Alarm
Acknowledge Change
Option
2. Re-connect wiring that was removed in step 3 "ECU
830 Module Removal". Reference Table 7.
Program/
Exit
Figure 16. Control Panel
2. Once the release knobs have been loosened, gently
lower the control panel. The backside of the ECU 830
control module is now accessible.
3. Remove all wiring connected to the existing ECU 830
control module.
4. Next, remove the four screws (Figure 17) that secure
the existing ECU 830 control module to the Control
Panel.
Table 7. ECU 835 Wire Connections
Pin Number
Wire Color
Quantity
3
Green
1
4
Red/Orange
1
5
White
1
6
Brown
1
8
White
1
8
White
1
9
Black
1
9
Black
1
12
Pink
1
13
Yellow
1
14
Black/Red
1
16
Red
1
37
White
1
38
Black
1
57
Brown
1
58
Red
1
ECU
830
RETAINING
NUT (4)
Figure 17. ECU 830 Module Removal
5. Discard the existing ECU 830 Module.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 8
DC CONTROL SPLIT LOOM HARNESS (ECU,
VOLTAGE SELECTOR SWITCH, ECU AND
CONTROL BOX SIDE
1. Continue routing the free end of the DC Control
split-loom harness through the bottom access hole
(Figure 18) on the Control Box.
GND.
1
BLK
2 3
YELLOW
2. Connect one end of the fuse holder wire (Figure 18)
to the 4-pin terminal block located at the rear of the
Control Box to terminal 4 (bottom).
DECAL PLACEMENT
DC CONTROL
SPLIT-LOOM
HARNESS
P/N EE58517
FROM TB1
CONTACTOR
J-BOX
1. Place Power Balance decal (P/N EE57143) onto
Control Panel as shown in Figure 19.
RED
BROWN
VOLTAGE
SELECTOR
SWITCH
1. Insert a 10 AMP fuse into the fuse holder (P/N 303110).
4. Once the wiring has been completed, raise the Control
Panel back onto the cabinet frame and secure by
turning the release knobs clockwise.
4
SPLICE
-LINE
ADD IN AMP
0
RED/WHT
FUSE 1
X
O
B
OL
CONTR
S
ACCES
HOLE
TERMINAL
42
Reference Figure 18.
3. Next, using a butt splice connector, connect the other
end of the fuse holder wire to the RED/WHITE wire.
GRN/WHT
4-PIN
TERMINAL
BLOCK
IN-LINE FUSE INSTALLATION
RED
PIN-57
JUMPER
WIRE
2. Next, place Patent Pending decal (P/N EE57145) onto
Control Panel as shown in Figure 19.
PIN-58
PIN-4
PIN-13
ECU 835
PIN-16
25
50
75
140
180
100
18
12
220
PSI
0
24
°F
VOLTS
100
260
6
30
DECREASE
INCREASE
OIL PRESS
WATER TEMP
BATTERY
½
Figure 18. DC Control Split-Loom Harness
120
150
180
60
RPMX10
E
F
FUEL
0
V
210
SPEED
U
2. Connect the YELLOW, RED and BROWN wires to
the ECU module (pins 13, 16 and 57 respectively) as
shown in Figure 18 and Table 6.
3. Next, connect the RED wire with the terminal ring to
pin 42 on the Voltage Selector Switch.
W
OFF
ECU
V-W
Series 800 Controller
Engine Started
Shutdown
W-U
U-V
OFF
Pre-Alarm
Screen
Alarm
Acknowledge Change
Option
Program/
Exit
4. Connect the GREEN/WHITE wire with the terminal ring
to the Control Box ground point.
PLACE
HERE
PLACE
HERE
PATENT PENDING
Figure 19. Decal Placement
3. Reconnect battery.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 9
TESTING
Once the Load Bank is installed and ready to test, the ECU
835 Controller must first be updated with the latest firmware
to support Load Bank operation.
NOTICE
The firmware file must be in the main directory (no
subfolders). Insert the flash drive into the USB port on
the back of the ECU835 controller.
1. Obtain ECU 835 firmware file 0-0-12-0 JD 0-2-0-13.pfw
and load to a USB flash drive.
2. Place ECU 835 into “Test Mode”. Test mode is
achieved by pressing and holding the hour check
button (Figure 20).
HOUR CHECK
BUTTON
8. Verify and change settings to match the settings shown
in Table 8. Use the “Set To” column values.
9. There are two set points that will need to be temporarily
set at low values for testing purposes. Once testing is
completed, set the Low Load Delay and High Load
Trip Reset settings back to the “Set To” column as
referenced in Table 8.
10. For testing, use the parameters listed below:
„„Low Load Delay, set to 2 minutes.
„„High Load Trip Reset, set to 1 minute.
11. The following test equipment will be required to
complete the testing:
„„A stopwatch to confirm load bank is operating at the
correct intervals.
„„External load bank capable of full load in each
voltage position.
„„An ammeter to verify current in each voltage mode.
12. Connect the battery terminals and prime the fuel
system. Check that oil, coolant and DEF fluid levels
are satisfactory.
Figure 20. Hour Check Button
3. Next, place the Auto-Off/Reset Manual Switch
(Figure 21) in the manual position.
AUTO
13. Verify the main circuit breaker is placed in the ON
position.
14. Place the voltage selector switch (Figure 22) in the
3ø-240/139 position.
MANUAL
OFF/RESET
Figure 21. Auto-Off/Reset Manual Switch
(Manual Position)
4. Release the hour check button. Once in test mode, log
onto the ECU835 with the MQ Password.
5. Next, go to advanced options and select upgrade
firmware.
6. Select browse for file, and then select the file from
the USB. Once selected proceed with the onscreen
instructions to complete the firmware update.
Figure 22. Voltage Selector Switch
3Ø-240/139 Position
7. Once the update is completed, log back on to the
ECU835 with the MQ password. Go to customer
options then go to load bank settings.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 10
15. Connect an external load bank to the output terminal
panel as shown in Figure 23 and set up for selected
voltage mode.
Low Load Delay
1. Start the genset and run at no load.
2. Using the voltage regulator adjustment knob, adjust
voltage for 3ø-240V
E
3-PHAS
VOLTMETER
100
0
INCREASE
MAIN CIRCUIT
BREAKER
500
600
DECREASE
VOLTAGE REGULATOR
ADJUSTMENT KNOB
Figure 23. External Load Bank
16. Place ammeter clamp around Line 1 (L1) on the main
circuit breaker.
240 300 400
Figure 25. Voltmeter/VR
3. Start stopwatch.
4. The genset should run without the load bank engaging
for the time set for “Low Load Delay”. The test value
should be 2 min, so after 2 min (may only take one min)
the load bank should automatically turn ON.
5. A powered on Load Bank is indicated by a small “L” on
the front screen of the ECU835 (Load Bank On). You
should also hear an audible change in the engine load.
L3
L1
L2
AMMETER
CLAMP
6. On line 1 of the main circuit breaker (Figure 24),
the current measured at the ammeter should be
approximately 48A with the voltage selector switch
set at 3Ø-240V position without additional load from
the external load bank. The internal load bank should
stay on indefinitely.
High Load Level
Figure 24. Attaching Ammeter Clamp
The next step will test to verify that the internal load bank
turns off if a high load level is reached.
1. With the genset still running and the internal load bank
on, begin applying load from the external load bank
and add load steps equal to a value of approximately
40% of rated load (22-23 kW) for a 70 kVA genset.
2. The internal load bank should remain on. Run for a
couple of minutes and then in one additional step, apply
an additional 25 kW step from the external load bank.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 11
3. This should be enough load to exceed the “High Load
Trip” set point and drop out the internal load bank. This
can be verified by a small “T” on the front display of the
ECU835 (Torque Exceeded).
4. The “T” should remain for the duration of the “High Load
Reset” (60 seconds for test). Once the ECU timer has
elapsed, the “T” will go away.
5. The ECU control module is now verifying if the load is
above the acceptable load setting (50%) which it should
be while at 80% external load. The internal load bank
should not attempt to reengage.
6. Remove the external load bank and begin a new
stopwatch sequence.
7. After the (Low Load Delay) timer elapses (approximately
2 minutes for test), the internal load bank should
come back on. This completes the test for this voltage
position.
Using the same procedure repeat for 3ø- 480V and
1ø 240V.
480V Position Load Bank Testing
For 3 ø- 480V, the load bank line current should be
about half of what was measured in the 3ø-240V mode,
approximately 24A. Add 25kW step then an additional
25 kW step to trip on High Load Trip.
240V Position Load Bank Testing
1. For 1ø-240V, the load bank line current should be
about 54A. This will only be on L1 and L3 when in
single phase mode.
2. Add 109 amps to trip on High Load Trip, usually a 50
kW step on a 3ø load bank.
3. As mentioned earlier once testing is completed, set
the Low Load Delay and High Load Trip Reset settings
back to the values as shown in the “Set To” column.
Reference Table 8.
„„Low Load Delay set back to 10 min.
„„High Load Trip Reset set back to 600 Seconds.
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 12
Table 8. ECU 835/840 MQ Customer Settings (Load Bank)
DCA70 JDT4 Interim
Firmware Version 0-0-12-0 JD 0-2-0-13.pfw
Set To:
Menu
Set Point Name
Default
Unit of Measure
Value
Load Bank Enable
1
1
1=ON 0=OFF
Low Load Trip
46
50
% Torque
Sufficient Load Trip
45
50
% Torque
High Load Trip
80
92
% Torque
Alt Low Load Trip
45
45
% Torque
Alt Sufficient Load Trip
45
45
% Torque
Alt High Load Trip
80
65
% Torque
Low DOC in Temp C
300
300
°C
Low Load Delay Min
10
10
Min
Load Bank Settings
Regen Low Load Delay
10
0
Sec
Load Bank Dwell Min
0
60
Min
High Load Second Trip
0.1
0.1
Sec
High Load Second Reset
60
600
Sec
Idle in Load Enable
0
0
1=ON 0=OFF
Idle in Load PA
3
3
Sec
Idle in Load SD
60
60
Sec
Excessive Idle Enable
0
0
1=ON 0=OFF
Excessive Idle PA
10
10
Min
Excessive Idle SD
15
15
Min
DPF TCON High Temp C
1700
1700
°C
DPF TCON High Temp Dwell M
1
1
Min
DPF TCON Low Temp C
-200
-200
°C
DPF TCON Low Temp Dewll M
1
1
Min
H Enable
0
0
1=ON 0=OFF
H Count
1
1
Load Bank 2
TDR Cycle Enable
0
0
1=ON 0=OFF
TDR Insuff Load Min
120
120
Min
TDR Loadbank On Min
90
90
Min
Fault Detect. Enable Second 30
5
5
Sec
Enable Load Always On
0
1
1=ON 0=OFF
Idle > Rated Reenable Sec
5
5
Sec
DCA70SSJU4i — LOAD BANK INSTRUCTIONS P/N EE58627 — REV. #1 (03/13/15) — PAGE 13
DCA70SSJU4i
19.6 kW Load Bank Installation
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
MQ Parts Department
Tel. (800) 421-1244
Fax (310) 537-3927
Service Department
800-421-1244
310-537-3700
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
Fax: 310-537-4259
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
Fax: 310-943-2238
CANADA
UNITED KINGDOM
Multiquip
Multiquip (UK) Limited Head Office
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
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