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MQ Power WHISPERWATT DCA600SSV4F3B Operation Manual

60 hz generator (volvo twd1672ge diesel engine)
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL
DCA600SSV4F3B
60 Hz GENERATOR
(VOLVO TWD1672GE DIESEL ENGINE)
INSTRUCTION MANUAL NO. C4844305204
Revision #1 (10/21/22)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA600SSV4F3B 60 Hz GENERATOR (VOLVO TWD1672GE DIESEL ENGINE) INSTRUCTION MANUAL NO. C4844305204 Revision #1 (10/21/22) To find the latest revision of this publication or associated parts manual, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA600SSV4F3B NOTICE 60 Hz Generator Specifications are subject to change without notice. Proposition 65 Warning ........... 2 Table of Contents ............. 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............14–15 General Information ..........

  • Page 4: Safety Decals

    SAFETY DECALS SAFETY DECALS NOTICE Safety decals are attached to the generator as shown in For safety decal part numbers, refer to the associated Figure 1. Keep these safety decals clean at all times. When parts manual. the safety decals become worn or damaged, contact your nearest dealer or the Multiquip Parts Department.

  • Page 5: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 6 „ NEVER use accessories or attachments that are not being used. The generator should be stored in a clean, dry location out of the reach of children and unauthorized recommended by MQ Power for this generator. Damage to the generator and/or injury to the user may result. personnel.
  • Page 7 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 8 „ The trailer should be adjusted to a level position at all times when towing. „ Refer to the MQ Power trailer manual for additional safety information. „ Raise and lock the trailer wheel stand in the upright position when towing.
  • Page 9 SAFETY INFORMATION ELECTRICAL SAFETY „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. „ NEVER touch the output terminals NOTICE during operation. Contact with the „...
  • Page 10 SAFETY INFORMATION EMISSIONS INFORMATION „ If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty NOTICE of water and contact the nearest doctor or hospital to seek medical attention. The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CAUTION (CO), hydrocarbons (HC), and nitrogen oxides (NOx)

  • Page 11: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Models DCA600SSV4F3B Type Revolving field, self-ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase Standby Output 528 kW (660 kVA) Prime Output 480 kW (600 kVA) 3Ø Voltage 208, 220, 240, 416, 440, 480V 1Ø...

  • Page 12: Dimensions

    DIMENSIONS TOP VIEW SIDE VIEW Table 3. Dimensions REAR VIEW (CONTROL PANEL VIEW) Reference Dimension Reference Dimension Letter in. (mm) Letter in. (mm) 26.97 (685) 20.87 (530) 27.36 (695) 40.94 (1,040) 40.94 (1,040) 196.85 (5,000) 20.87 (530) 18.90 (480) 39.57 (1,005) 102.49 (2,603) 35.43 (900) 64.96 (1,650)
  • Page 13 NOTES DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22) — PAGE 13...

  • Page 14: Installation

    GENERATOR GROUND LUG GROUND ROD GROUND CABLE REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22)
  • Page 15 INSTALLATION OUTDOOR INSTALLATION MOUNTING Install the generator in an area that is free of debris, The generator must be mounted on a solid foundation bystanders, and overhead obstructions. Make sure the (such as concrete) and set firmly on the foundation to generator is on secure, level ground so that it cannot slide isolate vibration of the generator when it is running.

  • Page 16: General Information

    „ Control Box (located behind control panel) Refer to Table 2 for engine specifications. • Automatic Voltage Regulator In keeping with MQ Power’s policy of constantly improving • Current Transformer its products, the specifications quoted herein are subject • Overcurrent Relay to change without prior notice.

  • Page 17: General Paralleling Information (Option)

    GENERAL PARALLELING INFORMATION (OPTION) The kVAR load sharing is achieved by increasing or NOTICE decreasing the field excitation to the system’s alternators. When the paralleling option is employed, the Basler As the field excitation of one generator set in a group is DGC-2020HD controller must be installed.
  • Page 18 GENERAL PARALLELING INFORMATION (OPTION) SEQUENCING ALARM SILENCE NOTICE Pre-Alarm Silence allows the user to suppress the toggling of the alarm screen when a new pre-alarm becomes active. Ethernet communication is required when the While a pre-alarm is active, pressing the Alarm Silence generators are configured for the sequencing mode button will suppress the fault display.
  • Page 19 GENERAL PARALLELING INFORMATION (OPTION) Preparation Ethernet Cable Connection 1. Make sure the generator is turned OFF and the engine 1. Connect a shielded CAT5E ethernet cable between is cool. port 1 on both generators as shown in Figure 4. 2. Disconnect any loads connected to the generator. 3.

  • Page 20: Major Components

    MAJOR COMPONENTS Table 5. Major Components ITEM NO. DESCRIPTION Muffler Assembly Generator Assembly Battery Assembly Engine and Radiator Assembly Aftertreatment Control Module Assembly DEF Tank Assembly Control and Operation Panel Assembly Digital Genset Controller Assembly Voltage Change-Over Board Assembly Main Circuit Breaker Assembly Fuel Tank Assembly Output Terminal Panel Assembly Figure 5.

  • Page 21: Control And Operation Panel

    CONTROL AND OPERATION PANEL Figure 6. Control And Operation Panel The definitions below describe the controls and functions of the control and operation panel (Figure 6). 1. Basler DGC-2020 Digital Genset Controller — 6. Control Power Switch — Set this switch to the ON Displays parameters (AC voltage, AC current, phase, position prior to operation.

  • Page 22: Basler Digital Genset Controller

    BASLER DIGITAL GENSET CONTROLLER LCD DISPLAY VOLT 60.0 HR : 3:58 DEF : 33 % 60 % 28.2 FUEL TEMP BATT Figure 7. Basler DGC-2020 The definitions below describe the controls and functions of the Basler DGC-2020 digital genset controller (Figure 7). Refer to the digital controller’s instruction manual for more information.
  • Page 23 BASLER DIGITAL GENSET CONTROLLER 2. Not In Auto Indicator — This red LED lights whenever 11. Arrow Pushbuttons — These four buttons are used the DGC-2020 is not operating in Auto mode. to navigate through the front panel display menus and to modify settings.

  • Page 24: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The output terminal panel (Figure 9) shown below is The output terminal panel (Figure 9) is provided with the provided for the connection of electrical loads. Lift up on following: the cover to gain access to receptacles and terminal lugs.
  • Page 25 OUTPUT TERMINAL PANEL FAMILIARIZATION 120-Volt AC GFCI Receptacles GFCI RECEPTACLES NOTICE It is recommended that the GFCI receptacles be tested LOAD when the generator is initially uncrated. The receptacles should then be tested daily at startup. There are two 120-volt, 20-amp GFCI (duplex NEMA 5-20R) receptacles provided on the output terminal panel.

  • Page 26: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD THREE-PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to ensure the wattage, amperage, frequency, power, use the following equation: and voltage requirements are satisfactorily supplied by the VOLTAGE ×...

  • Page 27: Powerbalance

    POWERBALANCE™ PowerBalance™ (Figure 12) is an optional load „ PowerBalance™ continuously monitors engine load by management solution that helps protect the engine generator sensing the engine exhaust temperature. from problems resulting from sustained low-load operations (defined as less than 30% of the generator full-load rating). POWERBALANCE™...

  • Page 28: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES VOLTAGE REGULATOR A wide range of voltages (Table 8) is available for many To obtain some of the voltages listed in Table 8 will require different applications. a fine voltage adjustment using the voltage regulator (Figure 14) located on the control panel.

  • Page 29: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES DECREASE INCREASE Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumper plates (6) on the voltage change-over board (Figure 15) and the Figure 17.
  • Page 30 OUTPUT TERMINAL PANEL CONNECTIONS 3-Phase 480-Volt UVWO Terminal Output Voltages Single-Phase 480-Volt UVWO Terminal Output Voltages 1. Jumper the voltage change-over board for 480-volt operation as shown in Figure 20. This configuration 1. Make sure the voltage change-over board is jumpered uses 6 jumper plates in 3 different positions.

  • Page 31: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK 5. If the engine oil level is low (Figure 25C), remove the cap from the oil filler port (Figure 26) and fill to a 1. To check the engine oil level, place the generator on safe operating level (max) as indicated by the dipstick secure, level ground with the engine stopped.
  • Page 32 INSPECTION/SETUP FUEL CHECK Refueling Procedure DANGER NOTICE Fuel spillage on a hot engine can cause a ALWAYS fill the fuel tank with clean, fresh #2 diesel fuel. fire or explosion. If fuel spillage occurs, NEVER fill the fuel tanks beyond their capacities. wipe up the spilled fuel completely to prevent fire hazards.
  • Page 33 INSPECTION/SETUP 2. Fill the trailer fuel tank first. The trailer fuel tank is 4. Once the trailer tank is full, the secondary, internal the primary fuel tank and has a larger fuel capacity. The tank can be filled (Figure 31). Notice how the level fuel in the trailer will be filtered and sent to the engine.
  • Page 34 INSPECTION/SETUP DIESEL EXHAUST FLUID COOLANT NOTICE Volvo recommends pre-diluted Volvo Penta Coolant VCS (yellow). See the Volvo engine owner’s manual for further ONLY fill the DEF tank with diesel exhaust fluid. Any details. other type of fluid may cause severe engine damage. WARNING Diesel exhaust fluid (DEF) is an aqueous solution When adding coolant/antifreeze mix to the...
  • Page 35 INSPECTION/SETUP Operation In Freezing Weather ENGINE AIR CLEANER When operating in freezing weather, be certain the proper Periodic cleaning/replacement of the air cleaner is amount of antifreeze (Table 12) has been added. necessary. Inspect the air cleaner in accordance with the Maintenance section of this manual.
  • Page 36 INSPECTION/SETUP BATTERY POSITIVE This unit is of negative ground. DO NOT connect in reverse. ALWAYS maintain battery fluid level between the specified marks. Battery life will be shortened if the fluid level is not properly maintained. Add only distilled water when replenishment is necessary.
  • Page 37 INSPECTION/SETUP Battery Switch WIRING Located in the engine compartment, the Battery switch Inspect the entire generator for bad or worn electrical wiring (Figure 39) connects and disconnects the battery. Place or connections. If any wiring or connections are exposed the switch in the ON position prior to starting the generator. (insulation missing) replace wiring immediately.

  • Page 38: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING 6. Connect the load to the receptacles or the output terminal lugs as shown in Figure 10. These load CAUTION connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup The engine’s exhaust contains harmful emissions.
  • Page 39 GENERATOR START-UP PROCEDURE (MANUAL) 2. Once the engine starts, the engine will run at low NOTICE idle (900 rpm) for approximately 30 seconds. During Oil pressure readings may be higher immediately after the warmup process, check for any abnormal noise, starting, especially in cold weather conditions, but vibration, or fluid leakage.

  • Page 40: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING (AUTO MODE) When starting the generator in Auto mode use the manual start-up procedure except where noted (see below). DANGER 1. Perform steps 1 through 7 in Before Starting found in Before connecting this generator to any the Generator Start-Up Procedure (Manual) section.

  • Page 41: Generator Shutdown Procedures

    GENERATOR SHUTDOWN PROCEDURES NORMAL SHUTDOWN PROCEDURE (MANUAL) 6. Allow sufficient time for adequate cooling, then inspect the entire generator for any damage or loosening of 1. Place the load’s ON/OFF switch in the OFF position. components that may have occurred during operation. 2.

  • Page 42: Maintenance

    MAINTENANCE Every 500 Every 1,000 Every 2,000 Table 13. Inspection/Maintenance Daily Hours Hours Hours Check Engine Oil and Coolant Levels Check Fuel Filter / Water Bowl Check Battery Fluid Level Check Air Cleaner Check for Leaks Visual Walk-Around Inspection Check Coolant Antifreeze Mixture Clean Air Cleaner Element Drain Bottom of Fuel Tank Drain Bottom of Fuel Pre-Filter...
  • Page 43 MAINTENANCE GENERAL INSPECTION Primary And Secondary Air Cleaner Elements Prior to each use, the generator should be cleaned and Every 250 hours: Remove the air cleaner elements and inspected for deficiencies. Check for loose, missing, or clean them with a light spray of compressed air. damaged nuts, bolts, or other fasteners.
  • Page 44 MAINTENANCE Air Cleaner Restriction Indicator Draining Fuel Filter Condensate The air cleaner is equipped with a restriction indicator 1. Place an appropriate container underneath the fuel (Figure 55). As the air cleaner element becomes clogged, filter to collect the condensate (water) and fuel as it air intake restriction increases and the indicator signal drains.
  • Page 45 MAINTENANCE 3. Clean the filter mating surface on the filter bracket 6. Lubricate the seal with diesel fuel. Screw the filter (Figure 57). onto the filter bracket by hand until the rubber seal just touches the mating surface. Then tighten another 4.
  • Page 46 MAINTENANCE CLEANING INSIDE THE FUEL TANK DRAINING THE ENGINE OIL If necessary, drain the fuel inside the fuel tank completely. 1. Run the engine until the engine coolant reaches a Using a spray washer (Figure 60), wash out any deposits temperature of 140°F (60°C).
  • Page 47 MAINTENANCE ENGINE OIL FILTER REPLACEMENT 6. Fill the engine crankcase with high-quality detergent oil classified “For Service CI-4.” Fill to the upper limit 1. Clean the area around the oil filter bracket (Figure 62). of the dipstick. DO NOT overfill. Refer to Table 2 for engine oil capacity.
  • Page 48 MAINTENANCE FLUSHING OUT THE RADIATOR 2. Open the cabinet door and remove the coolant drain bolt and O-ring (Figure 64), then allow the coolant to AND REPLACING COOLANT drain into a suitable container. WARNING Allow the engine to cool before flushing out the radiator.
  • Page 49 MAINTENANCE Cleaning The Radiator The radiator should be cleaned with water and a mild detergent when excessive amounts of dirt and debris have accumulated on the cooling fins or tubes. Use a soft brush. Be careful to not damage the radiator fins. NOTICE DO NOT use a high-pressure power washer (Figure 65) to clean the radiator.
  • Page 50 MAINTENANCE 3. Verify that the status LED on the corresponding GFCI 7. Repeat the above procedure for all other GFCI receptacle (Figure 68) is ON (GREEN). receptacles. GENERATOR STORAGE For long-term storage of the generator the following is GREEN recommended: STATUS LED (ON) „...
  • Page 51 MAINTENANCE ENGINE BLOCK HEATER AND When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the OPTIONAL INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES idea to apply power to the heater at all times.
  • Page 52 MAINTENANCE EMISSION CONTROL PREVENTIVE MAINTENANCE PROGRAMS The emission control system employed with this diesel Most challenging to a rental organization is the fact that a engine consists of a diesel oxidation catalyst (DOC) customer’s power assumptions may not meet the minimum and a selective catalytic reduction (SCR) catalyst load requirements of the power equipment selected.
  • Page 53 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) The amount of fluid in the DEF tank will be displayed on the digital controller during operation (Figure 75). Diesel engines can be run with a lean burn air-to-fuel ratio, to ensure the full combustion of soot and to prevent the exhaust of unburnt fuel.
  • Page 54 MAINTENANCE Table 14. DEF Level System Action 30 Minutes After Below 20% Below 15% Below 10% Below 5% Level Below 10% Pre-Alarm DEF Fluid Low DEF PRESVR DEF SEVERE DEF PRESVR DEF Fluid Low Screen Message DEF Low 15% INDUCMT INDUCMT INDUCMT Alarm Screen...

  • Page 55: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) DIAGNOSTIC MODE 2. Use the Arrow buttons (Figure 77) to navigate to the Alarms Status menu (METERING->ALARM-STATUS). The digital controller can be placed in Diagnostic mode, This will allow the operator to perform the following which will keep the key switch on for service tool purposes. diagnostics: To place the unit in Diagnostic mode the engine must be „...
  • Page 56 Refer to Table 16 for a complete list of engine protection devices and fault codes. If necessary, contact your nearest Automatic Shutdown System MQ Power dealer for additional technical support. This generator is equipped with engine protection devices When the unit is ready to restart, press the Off button on the digital controller.
  • Page 57 TROUBLESHOOTING (DIAGNOSTICS) Table 16. Automatic Engine Shutdown System Operating Circuit Breaker Engine Digital Controller Operating Condition/ Parameter Shutdown Display Message Set Point 27-1 UndVolt TRP Under Voltage — — When under voltage occurs (Pre-Alarm) Under Voltage 27-2 UndVolt TRP (Alarm) When under voltage occurs 59-1 OvrVolt TRP Over Voltage...

  • Page 58: Troubleshooting (Generator)

    TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 17.

  • Page 59: Generator Wiring Diagram (C4814005803)

    GENERATOR WIRING DIAGRAM (C4814005803) DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22) — PAGE 59...

  • Page 60: Engine Wiring Diagram (C4814107703)

    ENGINE WIRING DIAGRAM (C4814107703) PAGE 60 — DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22)

  • Page 61: Mcb Sequence Diagram (C4814211504)

    MCB SEQUENCE DIAGRAM (C4814211504) MCB SEQUENCE DIAGRAM NO. C4814211504 DCA600SSV4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (10/21/22) — PAGE 61...

  • Page 62: Engine Block Heater Wiring Diagram

    ENGINE BLOCK HEATER WIRING DIAGRAM BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) ENGINE BLOCK HEATER TEMP. BLACK 14 AWG. SWITCH LINE (L)120VAC INPUT HEATING 120 VAC WHITE 14 AWG. ELEMENT NEUTRAL (N) GREEN 14 AWG.

  • Page 63: Battery Charger Wiring Diagram (Option)

    BATTERY CHARGER WIRING DIAGRAM (OPTION) BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) TO CHASSIS GROUND GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).
  • Page 64 © COPYRIGHT 2022, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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