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MQ Power DCA1100SSC Operation Manual

Whisperwatt series 60hz generator (cummins qst30-g5 diesel engine)
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA1100SSC
60HZ GENERATOR
(CUMMINS QST30-G5 DIESEL ENGINE)
Revision #1 (01/17/18)
To find the latest revision of this
publication, 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 DCA1100SSC 60HZ GENERATOR (CUMMINS QST30-G5 DIESEL ENGINE) Revision #1 (01/17/18) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 3: Reporting Safety Defects

    18883274236 (TTY: 18004249153), go to http://www.nhtsa.dot.gov; or write Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safecar.gov. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 3...

  • Page 4: Table Of Contents

    Engine Block Heater Wiring Diagram (Option) ..50 Troubleshooting (Generator) ........51 Troubleshooting (Engine Controller) ...... 52 Diagnostic Display ..........53-54 NOTICE Specifications are subject to change without notice. PAGE 4 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 5: Safety Information

    COULD result in DEATH or SERIOUS INJURY. CAUTION Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. NOTICE Addresses practices not related to personal injury. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 5...
  • Page 6 „ ALWAYS store generator properly when it is not being used. Generator should be stored in a clean, dry location out of the reach of children and unauthorized personnel. PAGE 6 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 7 „ NEVER touch the hot exhaust manifold, local Health and Safety Administrator. muffl er or cylinder. Allow these parts to cool before servicing generator. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 7...
  • Page 8 „ NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death. PAGE 8 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 9 The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 9...

  • Page 10: Safety Information

    Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings. PAGE 10 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 11: Safety Labels

    Stop engine before servicing. B90400040 WHISPERWATT WARNING FAN SHROUD DIESEL FUEL can cause fire or explosion. Stop engine before fueling. Keep cigarettes, sparks and flame away. LITERS B90450000 DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 11...

  • Page 12: Safety Labels

    A90400001 ENGINE EXHAUST can cause severe injury or death. Use only in open, well ventilated areas or vent exhaust outside. B90420000 Figure 2. Safety Labels 2 PAGE 12 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 13: Specifications

    46.5 gal. (176 L)/hr at 75% load Fuel Consumption 33.0 gal. (125 L)/hr at 50% load 18.3 gal. (69.3 L)/hr at 25% load Battery 12V 200Ah x 4 (24V System) DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 13...

  • Page 14: Dimensions

    44.49 (1,130) 43.50 (1,105) 43.50 (1,105) 32.09 (815) 30.12 (765) 41.14 (1,045) 39.37 (1,005) 272 (6,910) 40.94 (1,040) 114.1 (2,900) 30.12 (765) 86.61 (2,200) 43.50 (1,105) PAGE 14 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 15 NOTES DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 15...

  • Page 16: Installation

    BE CONNECTED TO A GROUND ROD GROUND CABLE I M U M I N REFERENCE 8 ’ ( NEC 250 Figure 4. Typical Generator Grounding Application PAGE 16 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 17: Installation

    ALWAYS consult with a licensed They are to resist damage to the bottom of the generator electrician. and to maintain alignment. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 17...

  • Page 18: General Information

    ±.25%. LOAD CABLES When connecting load to generator be sure to select correct size of cables to handle full load/amperage (1323 amps @480 VAC). PAGE 18 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 19: Major Components

    Output Terminal Assembly Denyo Battery Assembly Engine And Radiator Assembly Engine Control Panel Assembly Diagnostic Guage Assembly Battery Switch Generator Control Panel Assembly Figure 5. Major Components DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 19...

  • Page 20: Generator Control Panel

    7. AC Voltmeter — Indicates the output voltage present at the U,V, and W Output Terminal Lugs. PAGE 20 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 21: Engine Control Panel

    60 Hz operation. This meter should indicate (98 kPa). This condition will cause the engine 1800 RPM’s when the rated load is applied. to shut down. This is considered a major fault. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 21...

  • Page 22: Engine Control Panel

    Gauge Unit Assembly, Figure 7, items C and D. PAGE 22 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 23: Output Terminal Panel Familiarization

    1100 3Ø, 480 VAC BUS BAR OUTPUT TERMINALS GROUND DEDICATED TERMINAL BLUE WHITE GREEN BLACK VOLTAGE OUTPUT TERMINAL PANEL Figure 8. Output Terminal Panel (Bus Bars) DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 23...

  • Page 24: Output Terminal Panel Familiarization

    G R E E GROUND CONNECTION MUST BE USED AT ALL TIMES BUS BAR (4) I T E NEUTRAL LOAD Figure 10. Connecting Loads PAGE 24 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 25: Load Application

    When connecting resistance loads such as incandescent lamps or electric heaters, aload of up to the generator's rated output (kW) can be connected. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 25...

  • Page 26: Generator Outputs

    Figure 13. AC Ammeter Change-Over Switch NOTICE The ammeter gauge will only show a reading when the bus bar output terminal lugs are connected to a load and is in use. PAGE 26 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 27: Output Terminal Panel Connections

    Figure 15. Voltage Regulator Knob NOTICE Use the voltage regulator knob to adjust the UVW output for 440, 460 or 480 VAC. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 27...

  • Page 28: Inspection/Setup

    „ API Service Classification CC/SD „ API Service Classification CC/SE „ API Service Classification CC/SF 1100 Table 8. Recommended Motor Oil INTERNAL FUEL TANK Figure 17. Internal Fuel Tank System PAGE 28 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 29 Fuel expands when heated (Figure 21). NOTICE ONLY use #2 diesel fuel when refueling. Figure 21. Fuel Expansion DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 29...
  • Page 30 NEVER place hands near the belts or fan while the generator set is running. When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. PAGE 30 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 31 Tighten all hose clamps and check hoses for leaks. If any hose (fuel or oil) lines are defective replace them Figure 23. Battery Connections immediately. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 31...

  • Page 32: Generator Startup Procedure (Manual)

    2. Verify that the main circuit breaker “OFF” lamp (Figure 25) is lit (ON). CORRECT Figure 27. Enclosure Doors Figure 25. Main Circuit Breaker OFF Lamp PAGE 32 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 33 6. If the engine is running smoothly, place the engine Engine Started speed switch (Figure 32) in the HIGH (up) position. Figure 36. Engine Started LED (ON) DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 33...

  • Page 34: Generator Startup Procedure (Manual)

    18. The generator will run until manually stopped or an Under normal operating conditions this speed is abnormal condition occurs. approximately 1800 RPM’s. RPMX10 SPEED Figure 40. Engine Tachometer Gauge PAGE 34 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 35: Generator Startup Procedure (Auto Mode)

    NOTICE When the ECU control switch is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 35...

  • Page 36: Generator Shutdown Procedures

    Figure 48. Battery Switch (OFF) 7. Remove all loads from the generator. 8. Inspect entire generator for any damage or loosening of components that may have occurred during operation. PAGE 36 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 37: Maintenance (Engine)

    250 hours operation time. The carbon will be easier to be generated when the unit operates at less then 30% of rated power. In this case, perform the above procedures at shorter interval time. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 37...
  • Page 38 Change air cleaner more frequently if these conditions Operating the engine with loose or damaged air cleaner exist. components could allow unfiltered air into the engine causing premature wear and failure. PAGE 38 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 39 L (LOWER LIMIT) NOTICE Figure 52. Dipstick Engine Oil Level For composite oil pans always install a new sealing washer. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 39...
  • Page 40 The lubricating oil filter should be full of oil at engine start-up to prevent engine damage. 4. Coat the rubber seal (gasket) surface of each oil filter (Figure 55B) with clean 15W-40 engine oil. PAGE 40 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 41 DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns. Figure 58. Draining Engine Coolant DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 41...
  • Page 42 COOLANT FILTERS (2) Figure 59. Coolant Filters Removal 3. Coat the rubber seal (gasket) surface of each coolant filter (Figure 60) with clean 15W-40 engine oil. PAGE 42 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 43 „ Fuel Tank Lining — inspect the fuel tank lining for signs Figure 62. Fuel Water Separator of excessive amounts of oil or other foreign matter. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 43...
  • Page 44 Figure 64. Drive Belt Inspection 2. If the drive belt is frayed, punctured, or material is missing DO NOT use drive belt. PAGE 44 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 45 RED 16 AWG. OUTPUT TERMINAL PANEL ASSEMBLY BATTERY CHARGER/ ENGINE BLOCK HEATING ELEMENT 120 VAC INPUT RECEPTACLE Figure 65. Battery Charger and Jacket Water Heater Power Connections DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 45...

  • Page 46: Generator Wiring Diagram

    YELLOW 22: 22 mm GREEN LIGHT BLUE 14: 14 mm GRAY LIGHT GREEN 8 mm VIOLET ORANGE 5.5: 5.5 mm PINK NO MARK WIRE SIZE: 1.25 PAGE 46 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 47: Generator Wiring Diagram (Main Breaker)

    CIRCUIT BREAKER (OFF) LAMP 8 mm VIOLET ORANGE PINK 5.5: 5.5 mm NO MARK WIRE SIZE: 1.25 CONTROL BOX SIDE CONTROL PANEL SIDE CONNECTOR (VIEW FROM INSERTING WIRE SIDE) DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 47...

  • Page 48: Engine Wiring Diagram

    ENGINE WIRING DIAGRAM COLOR CODE SYM. WIRE COLOR SYM. WIRE COLOR BLACK BLUE WHITE BROWN YELLOW GREEN LIGHT BLUE GRAY LIGHT GREEN VIOLET ORANGE PINK PAGE 48 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 49: Battery Charger Wiring Diagram (Option)

    NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE). RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY. 20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE). CORD, CAROL 3/C 14 AWG., P/N EE56557. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 49...

  • Page 50: Engine Block Heater Wiring Diagram (Option)

    NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE). RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY. 20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE). CORD, CAROL 3/C 14 AWG., P/N EE56557. PAGE 50 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 51: Troubleshooting (Generator)

    Check load and repair. Over current? Confirm load requirements and reduce. Circuit Breaker Tripped Defective circuit breaker? Check and replace. Over current Relay actuated? Confirm load requirement and replace. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 51...

  • Page 52: Troubleshooting (Engine Controller)

    Refer to dealer. Magnetic pick up out of adjustment? Adjust magnetic pick up. Loss of MPU light(s) or on. Magnetic pick up dirty? Clean magnetic pick up. PAGE 52 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)

  • Page 53: Diagnostic Display

    4. Right Arrow Button – Press this button to scroll through the screen either moving the parameter selection toward the right or downward. DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 53...
  • Page 54 3. Place the ECU Auto Start/Stop Switch in the desired position (Auto or Manual). 4. Restart generator as outlined in the Operation Section of this mamual. PAGE 54 — DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18)
  • Page 55 NOTES DCA1100SSC 60 HZ GENERATOR • OPERATION MANUAL — REV. #1 (01/17/18) — PAGE 55...
  • Page 56 © COPYRIGHT 2018, 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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