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MQ Power WHISPERWATT DCA400SSI4F3B Operation Manual

Isuzu bq-6wg1x diesel engine)
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL
DCA400SSI4F3B
60 Hz GENERATOR
(ISUZU BQ-6WG1X DIESEL ENGINE)
INSTRUCTION MANUAL NO. C3844303904B
Revision #0 (09/21/22)
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 DCA400SSI4F3B 60 Hz GENERATOR (ISUZU BQ-6WG1X DIESEL ENGINE) INSTRUCTION MANUAL NO. C3844303904B Revision #0 (09/21/22) 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 — DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA400SSI4F3B 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 DCA400SSI4F3B Revolving field, self-ventilated, Type open protected type synchronous generator Armature Connection Star with Neutral Phase Standby Output 336 kW (420 kVA) Prime Output 320 kW (400 kVA) 3Ø Voltage 208, 220, 240, 416, 440, 480V 1Ø...

  • Page 12: Dimensions

    DIMENSIONS TOP VIEW SIDE VIEW FRONT VIEW Figure 2. Dimensions Table 3. Dimensions Reference Reference Dimension in. (mm) Dimension in. (mm) Letter Letter 31.89 (810) 22.83 (580) 22.83 (580) 31.89 (810) Denyo 25.98 (660) 21.47 (545) 27.17 (690) 30.71 (780) 25.60 (650) 181.10 (4,600) 27.17 (690)
  • Page 13 NOTES DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22) — 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 — DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22)
  • 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

    Refer to • Automatic Voltage Regulator Table 2 for engine specifications. • Current Transformer In keeping with MQ Power’s policy of constantly improving 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, press the Alarm Silence generators are configured for the sequencing mode button to 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. Generator Major Components Item No. Description Muffler Assembly Air Cleaner Assembly Generator Assembly Battery Assembly Engine Assembly Fuel Tank Assembly Emergency Stop Switch Output Terminal Panel Assembly Circuit Breaker Assembly Digital Genset Controller Assembly Voltage Change-Over Board Figure 5.

  • Page 21: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL Figure 6. Engine/Generator Control Panel The definitions below describe the controls and functions of the control and operation panel (Figure 6). 1. Basler DGC-2020 Digital Genset Controller — 5. Main Circuit Breaker — This 3-phase, 1000-amp, Displays parameters (AC voltage, AC current, phase, main circuit breaker protects the U, V, and W output frequency, fuel level, DEF level, oil pressure, engine run terminal lugs from overload.

  • 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 NOTICE It is recommended that the GFCI receptacles be tested when the generator is initially uncrated. The receptacles SINGLE-PHASE CS-6369 240/139 VAC TWIST-LOCK should then be tested daily at startup. 50-AMP OUTPUT RECEPTACLES There are two 120-volt, 20-amp GFCI (duplex NEMA 5-20R) receptacles provided on the output terminal panel.
  • Page 26 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads OVERCURRENT RELAY An overcurrent relay (Figure 13) is connected to the Loads can be connected to the generator via the output terminal panel, convenience receptacles, or optional main circuit breaker. In the event of an overload, both the cam-loks (Figure 12).

  • Page 27: 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 28: Powerbalance

    POWERBALANCE™ PowerBalance™ (Figure 14) 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 29: 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 control knob (Figure 16) located on the control panel.

  • Page 30: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator control knob (Figure 19) clockwise to increase voltage output as needed. Turn Various output voltages can be obtained using the UVWO counterclockwise to decrease voltage output. output terminal lugs. The voltages at the terminals are dependent on the placement of the jumper plates (6) DECREASE INCREASE...
  • Page 31 OUTPUT TERMINAL PANEL CONNECTIONS Single-Phase 480-Volt NOTICE UVWO Terminal Output Voltages ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility exists 1. Make sure the voltage change-over board is jumpered of arcing that could cause a fire. for 480-volt operation as shown in Figure 22.

  • Page 32: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK 5. If the engine oil level is low (Figure 27C), remove the cap from the oil filler port (Figure 28) 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 33 INSPECTION/SETUP FUEL CHECK 1. Level Tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the DANGER tank before reaching full capacity (Figure 30). Fuel spillage on a hot engine can cause a CAUTION fire or explosion.
  • Page 34 INSPECTION/SETUP COOLANT Fuel EXPANDS (ANTIFREEZE/SUMMER COOLANT/WATER) When Heated! Isuzu recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the Isuzu Figure 33. Fuel Expansion engine owner’s manual for further details. DIESEL EXHAUST FLUID WARNING When adding coolant/antifreeze mix to the...
  • Page 35 INSPECTION/SETUP Operation In Freezing Weather FAN BELT TENSION When operating in freezing weather, be certain the proper A slack fan belt may contribute to overheating, or to amount of antifreeze (Table 12) has been added. insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Table 12.
  • Page 36 INSPECTION/SETUP BATTERY POSITIVE This unit is of negative ground. DO NOT connect in reverse. ALWAYS maintain the 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 PIPING AND HOSE CONNECTIONS Located in the engine compartment, the Battery switch Inspect all piping, oil hose, and fuel hose connections for (Figure 39) connects and disconnects the battery. Place wear and tightness. Tighten all hose clamps and check the switch in the ON position prior to starting the generator.

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

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING 7. Close all engine enclosure doors (Figure 42). CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. CORRECT INCORRECT WARNING Figure 42. Engine Enclosure Doors NEVER manually start the engine with the main, GFCI, STARTING (MANUAL) or auxiliary circuit breakers in the ON (closed) position.
  • Page 39 GENERATOR START-UP PROCEDURE (MANUAL) 3. The controller display will indicate the 60-cycle output 10. Observe the amperage reading on the controller display frequency in HERTZ (Figure 44C). (Figure 44B) and verify that it is the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

  • 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) NORMAL SHUTDOWN PROCEDURE (AUTO) 1. Place the load’s ON/OFF switch in the OFF position. When the remote contacts are opened, the engine will stop. To exit Auto mode, press the OFF button on the 2.

  • Page 42: Maintenance

    MAINTENANCE Every Every 500 Every 1,000 Table 13. Inspection/Maintenance Daily Other Hours Hours Hours Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Battery Fluid Level Check Air Cleaner Check for Leaks Visual Walk Around Inspection Clean Air Cleaner Element Drain Bottom of Fuel Tank Replace Engine Oil and Oil Filter* Replace Fuel Filter Elements...
  • 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 The Fuel Filter The air cleaner is equipped with a restriction indicator 1. Loosen the air bleeder plug (Figure 53) on the fuel (Figure 52). As the air cleaner element becomes clogged, filter body. air intake restriction increases and the indicator signal shows RED, indicating that the element needs to be 2.
  • Page 45 MAINTENANCE Fuel Filter Element Replacement REMOVING WATER FROM THE FUEL TANK 1. Using a filter wrench, remove the element case from After prolonged use, water and other impurities accumulate the fuel filter body (Figure 54). in the bottom of the fuel tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.
  • Page 46 MAINTENANCE DRAINING ENGINE OIL ENGINE OIL FILTER REPLACEMENT 1. Run the engine until the engine coolant reaches a NOTICE temperature of 140°F (60°C). Filter head appearance may vary. 2. Turn the engine OFF. 3. Remove the oil dipstick from its holder. 1.
  • Page 47 MAINTENANCE 6. Run the engine for several minutes. Watch for oil 3. After the coolant has completely drained, place the coolant drain valve in the CLOSED position. leakage. Shut the engine down and allow it to sit for several minutes. Top off the oil to the upper limit on 4.
  • Page 48 MAINTENANCE DRIVE BELT TESTING THE GFCI RECEPTACLE Drive Belt Tension NOTICE The GFCI receptacle is designed to interrupt power A slack drive belt may contribute to overheating or when a ground fault exists to prevent injuries and shock insufficient charging of the battery. Adjust the drive belt in hazards.
  • Page 49 MAINTENANCE GENERATOR STORAGE 4. Press the TEST button (Figure 64) on the GFCI receptacle and verify that the status LED turns OFF. For long-term storage of the generator the following is recommended: „ Drain the fuel tank completely. Treat with a fuel stabilizer if necessary.
  • Page 50 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 51 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 52 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) Refer to Table 14 for digital controller messages displayed during SCR Purge operation. Diesel engines can be run with a lean burn air-to-fuel ratio, Table 14. SCR Purge Controller Messages to ensure the full combustion of soot and to prevent the exhaust of unburnt fuel.
  • Page 53 MAINTENANCE Automatic Purge Operation While a Forced Purge operation is in progress, the Alarm lamp will begin flashing (red) and the message “SCR The purging operation is automatically performed every Forced Purge” will appear on the controller screen 30 hours. The Alarm lamp will begin flashing (red) and the (Figure 71).
  • Page 54 MAINTENANCE DIESEL EXHAUST FLUID (DEF) The amount of fluid in the DEF tank will be displayed on the digital controller during operation (Figure 73). The Diesel Exhaust Fluid (DEF) indicator (Figure 72) will be displayed on the digital controller during either of the following operating conditions: „...
  • Page 55 MAINTENANCE INDUCEMENT NOTICE When the system senses improper usage such as no Replace the DEF filter (located in the urea SCR system supply of DEF, use of poor quality DEF, problems with supply module) every 1,000 hours of operation. Refer DEF dosing, or disconnection of sensors, a warning will be to the Replacement of DEF Filter section in the Isuzu issued before the situation becomes critical.
  • Page 56 MAINTENANCE ESCAPE MODE 6. When Escape mode is enabled, the Alarm lamp will flash and the message “Escape Mode” will appear When emergency shutdown occurs, inspection and on the Pre-Alarm screen. repair should generally be performed promptly. However, 7. Press the Run button (Figure 75) to start the engine. if emergency protective measures are necessary which require the unit to be running, the engine can be started in Escape mode, which allows the unit to run for 30 minutes.
  • Page 57 MAINTENANCE Escape Mode Deactivation 1. Press the Off button on the digital controller (Figure 76) to stop the engine. The engine will stop after a 1-minute cool-down process. Figure 76. Digital Controller (OFF Button) 2. After the engine has stopped completely, place the Control Power switch in the OFF position (Figure 77).

  • Page 58: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) DIAGNOSTIC MODE The digital controller can be placed in Diagnostic mode which will keep the key switch on for service tool purposes. To place the unit in Diagnostic mode, the engine must be turned OFF. 1. Press and hold the Alarm Silence button and the Lamp Test button (Figure 78) simultaneously for 5 seconds.
  • Page 59 Allow a sufficient cooling period, then inspect the unit and repair the problem before restarting operation. If necessary, contact your nearest MQ Power dealer for additional technical support. When the unit is ready to restart, press the Off button on the digital controller.
  • Page 60 TROUBLESHOOTING (DIAGNOSTICS) Table 18. Automatic Engine Shutdown System Operating Circuit Breaker Engine Digital Controller Operating Condition/ Parameter OFF LED Shutdown LED Display Message Set Point 27-1 UndVolt TRP Under Voltage — — When under voltage occurs (Pre-Alarm Screen) 27-2 UndVolt TRP Under Voltage When under voltage occurs (Alarm Screen)

  • Page 61: 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 19 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 19.

  • Page 62: Generator Wiring Diagram (C3814006203A)

    GENERATOR WIRING DIAGRAM (C3814006203A) PAGE 62 — DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22)

  • Page 63: Engine Wiring Diagram (C3814106503B)

    ENGINE WIRING DIAGRAM (C3814106503B) DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22) — PAGE 63...

  • Page 64: Controller Wiring Diagram (A) (C3814105803)

    CONTROLLER WIRING DIAGRAM (A) (C3814105803) PAGE 64 — DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22)

  • Page 65: Controller Wiring Diagram (B) (C3814105903)

    CONTROLLER WIRING DIAGRAM (B) (C3814105903) DCA400SSI4F3B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (09/21/22) — PAGE 65...

  • Page 66: 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 67: 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 68 © 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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