Multiquip MQP20P User Manual
OPERATION AND PARTS MANUAL
MODEL MQP20P
20KW STANDBY GENERATOR
(PERKINS 404D-22 DIESEL ENGINE)
Revision #1 (11/28/11)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
NOTES
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 3
TABLE OF CONTENTS
MQP20P Standby Generator
Proposition 65 Warning ........................................... 2
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information ..............................................6-11
Specifications ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................14-15
General Information .......................................... 16-17
Major Components ................................................ 18
Basic Engine Components .................................... 19
Digital Controller Panel .......................................... 20
Connector Outlet Box And Main Circuit Breaker ... 21
Load Application/Generator Output ....................... 22
Inspection/Setup ............................................... 23-26
Startup .............................................................. 27-29
Protective Devices ................................................. 30
Transporting ........................................................... 31
Maintenance ..................................................... 32-35
Troubleshooting (Generator) .................................. 36
Troubleshooting (Engine) ....................................... 37
Troubleshooting (Controller) ............................. 38-39
Troubleshooting (Voltage Regulator) ..................... 40
Maintenance Parts Locator .................................... 41
Generator Wiring Diagram (Single Phase) ....... 42-43
Generator Wiring Diagram (Three Phase) ........ 44-45
Explanation Of Code In Remarks Column............. 46
Suggested Spare Parts ......................................... 47
Component Drawings
Housing Assy. ................................................... 48-49
Engine And Generator Mounting Assy. ............. 50-51
Fuel Assy. ......................................................... 52-53
Electrical Assy. .................................................. 54-55
Jacket Water Heater Assy. ................................ 56-57
Solenoid Assy. .................................................... 5-59
Radiator Assy. ................................................... 60-61
Air Filter Assy. ................................................... 62-63
Engine Exhaust Assy. ....................................... 64-65
Engine Oil Assy. ................................................ 66-67
Control Panel Assy. ........................................... 68-69
Controller Assy. ................................................. 70-71
Saddlebox Assy. ...............................................72-73
Circuit Breaker Assy. ........................................... 74-5
Camlok Assy. .................................................... 76-77
Terms And Conditions Of Sale — Parts ................ 78
NOTICE
Specifications and part numbers are subject to change
without notice.
PAGE 4 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
If you have an MQ Account, to obtain a Username
Effective:
Choose from three easy options:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specifi cation Information
Goto www.multiquip.com and click on
Order Parts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
and Password, E-mail us at: parts@multiquip.
com.
To ob tain an MQ Ac cou nt , co nta ct yo ur
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
When ordering parts, please supply:
❒ Dealer Account Number
❒ Dealer Name and Address
❒ Shipping Address (if different than billing address)
❒ Return Fax Number
❒ Applicable Model Number
❒ Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
Potential hazards associated with the operation of this
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
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.
PAGE 6 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
SAFETY INFORMATION
GENERAL SAFETY
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
Also, know the
and
This information will be invaluable in
emergency or safety devices.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
ensure generator is on level ground before use.
keep the machine in proper running condition.
store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site.
phone numbers of the nearest ambulance, doctor
fi re department.
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any
These devices are intended for operator safety.
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS
ALWAYS
Fix damage to machine and replace any broken parts
immediately.
ALWAYS
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 7
ENGINE SAFETY
NOTICE
run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
Wet stacking is a common problem with diesel engines
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
applied to relieve the condition. It can reduce the system
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
from the engine exhaust. Spark arresters are qualifi ed
SAFETY INFORMATION
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
D O NOT pl ace h ands or fing ers inside e ngine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
NEVER
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
which are operated for extended periods with light or
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
PAGE 8 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
to prevent accidental discharge of sparks or fl ames
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
FUEL SAFETY
DANGER
Make sure the hitch and coupling of the towing vehicle
NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Trailer tires should be infl ated to 50 psi cold.
safety
attach trailer’s safety chains to towing
make sure the vehicle and trailer directional,
unless
posted otherwise. Recommended off-road towing is not to
Avoid sudden stops and starts. This can cause skidding,
Trailer should be adjusted to a level position at all times
rolling
underneath the trailer’s bumper
Use the trailer’s swivel jack to adjust the trailer height to
SAFETY INFORMATION
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke ar ound or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transpor tation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
CAUTION
ALWAYS inspect the hitch and coupling for wear.
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a
chain.
ALWAYS properly
vehicle.
ALWAYS
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
The maximum speed for highway towing is 55 MPH
exceed 15 MPH or less depending on type of terrain.
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent
while parked.
Place support blocks
to prevent tipping while parked.
a level position while parked.
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 9
ELECTRICAL SAFETY
DANGER
Make sure power cables are securely connected to the
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
make sure that electrical circuits are properly
Severe injury or death by
can result from operating an ungrounded
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
SAFETY INFORMATION
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Chart in this manual.
Grounding Safety
DANGER
ALWAYS
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator.
electrocution
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
BATTERY SAFETY
ENVIRONMENTAL SAFETY
pour waste, oil or fuel directly onto the ground,
SAFETY INFORMATION
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. 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.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT
down a drain or into any water source.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 11
Model
Type
Armature Connection
Phase
Standby Output
Prime Output
Voltage
Power Factor
Frequency
Speed
Aux. AC Power
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
SPECIFICATIONS
Table 1. Generator Specifications
MQP20P
Rotating field, 4-pole,
brushless, shunt excitation design
High Voltage Series High Voltage Series (WYE)
Single Three
20 kW (25 kVA) 20 kW (25 kVA)
17 kW (21.25 kVA) 17 kW (21.25 kVA)
240 V 277Y/480V
1.0 0.8
60 Hz
1800 rpm
Single Phase, 60 Hz
Table 2. Engine Specifications
Perkins 404D-22 Tier 4
4 cycle, indirect injection
4 cylinders In -Line
3.30 in. x 3.93 in. (84 mm x 100 mm)
135 cu. in. (2.2 liters)
32.6 HP at 1800 rpm
Electric
0.9 gal. (3.6 liters)
2.8 gal. (10.6 liters)
#2 Diesel Fuel
126 gal. (475 liters)
1.5 gal. (5.7 L)/hr at full load 1.2 gal. (4.5 L)/hr at 3/4 load
0.8 gal. (3.0 L)/hr at 1/2 load 0.7 gal. (2.6 L)/hr at 1/4 load
12 VDC
PAGE 12 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
G
DIMENSIONS
A
M
J
L
H
D
K
C
E
F
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
A 74 in. (1879.6 mm.) G 50.19 in. (1274.8 mm.)
B 32 in. (812.8 mm.) H 35.31 in. (896.9 mm.)
C 77 in. (1955.8 mm.) J 17.5 in. (444.5 mm.)
D 73.06 in. (1855.7 mm.) K 15 in. (381 mm.)
E 62 in. (1574.8 mm.) L 54.06 in. (1373.1 mm.)
F 82.5 in. (2095.5 mm.) M 35.5 in. (901.7 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
B
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 13
INSTALLATION
GROUND ROD
FOR EARTH
GROUND
GROUND CABLE
GENERATOR
GROUND LUG
CONNECT TO
BUILDING
GROUND
8 FT. MINIMUM
REFERENCE
NEC 250-52(C)
NOTE: GROUND LUG
MUST BE INSTALLED BY USER
PAGE 14 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
Figure 2. Typical Generator Grounding Application
INSTALLATION
OUTDOOR INSTALLATION
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected
from excessive moisture. Failure to do so will result in
deterioration of the insulation and will result in short circuits
and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
INDOOR INSTALLATION
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guidelines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper — 8 AWG (5.3 mm2)
b. Aluminum — 6 AWG (8.4 mm2)
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must sit at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1).
NOTICE
When connecting the generator to any building electrical
system, ALWAYS consult a licensed electrician.
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 15
GENERAL INFORMATION
GENERATOR
This generator (Figure 3) is a high-quality, reliable, backup
power source used by telecommunications companies to
keep their networks connected.
CONTROL PANEL (MEC 20™ Digital Controller)
AC Metering Display
• Voltage/Amperage / Frequency
• Generator Phase Voltage / Current
• Generator Frequency
Engine Information Display
• Engine Temperature / Oil Pressure (psi)
• Battery Voltage (DC) / Tachometer
• Hourmeter
Minor Fault Warning Display
• Switch Not In Auto
• Low Fuel Level
• Low Oil Pressure Alarm
• Low Engine Temperature
• High Engine Temperature Alarm
• Low Battery Voltage
• High Battery Voltage
• Weak Battery Condition
• Battery Charger Input Fail
• Undervoltage
• Over / Underfrequency
• Overcurrent
Major Fault Shutdown Display
• Overvoltage
• Emergency Stop
• Loss Of Speed
• Overcrank
• Overspeed
• Low Oil Pressure
• High Engine Temperature
• Low Coolant Level
• Spare Programmable Digital Faults
Switches And Operating Controls
• Run / Off / Auto / Load Test Buttons
• Decrement / Increment / Previous
(Exit) /Next (Enter) Program Buttons
• Emergency Stop Button
• Audible Alarm Horn – 80 dB(A) at 2 ft.
• Alarm Horn Silence Button
• Lamp Test Button
• Fault Reset Function
• RJ45 Remote Communications,
External Expansion Module Ports
Timer Countdown Display
• Engine Start Delay
• Oil Bypass
• Overcrank
• Cycle Crank
• Starter Re-engage Delay
• Bypass Delay
Control LED Indicators
• Switch Position (Run,Off,Auto,Test)
• Common Alarm (Minor Fault)
• Common Shutdown (Major Fault)
• Generator Ready (When in Auto)
• Speed Signal
• Emergency Stop
Diagnostic LED Indicators:
• Run Output Energized
• Crank Output Energized
• Remote Start Signal Initiated
• Common Fail Output Energized
• Watchdog - CPU Running
• Programmable Output Contacts
CAMLOK OUTLET BOX PANEL
The “Camlok Panel” is provided with the following receptacles:
Ground (GRND.) - Green
Neutral (NEUT.) - White
LEG 1 - Black
LEG 2 - Red
LEG 3 - Blue
PAGE 16 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
GENERAL INFORMATION
PRINCIPLE OF OPERATION
This generator is a brushless, self-excited, externally
voltage regulated, synchronous AC generator. The
generator is made up of six major components: main stator
(armature), main rotor (field), exciter stator (field), exciter
rotor (armature), rectifier assembly, and voltage regulator.
The generator's exciter consists of a stationary field and
a rotating armature. The stationary field (exciter stator)
is designed to be the primary source of the generator's
residual magnetism. This residual magnetism allows the
exciter rotor (armature) to produce AC voltage even when
the exciter stator (field) is not powered. This AC voltage
is rectified to DC by the rotating rectifier assembly and
fed directly to the main rotor (field). As the generator
shaft continues to rotate, the main rotor (field) induces a
voltage into the generator's main stator (armature). At rated
speed, the main stator's voltage produced by the residual
magnetism of the exciter allows the automatic voltage
regulator to function.
The regulator provides voltage to the exciter resulting in
a build-up of generator terminal voltage. This system of
using residual magnetism eliminates the need for a special
field flashing circuit in the regulator. After the generator
has established the initial residual voltage, the regulator
provides a controlled DC field voltage to the exciter stator
resulting in a controlled generator terminal voltage.
VOLTAGE REGULATION
In the standard configuration (shunt excited), the automatic
voltage regulator receives both its input power and voltage
sensing from the generator's output terminals. The regulator
automatically monitors the generator's output voltage
against an internal reference set point and provides the
necessary DC output voltage to the exciter field required
to maintain constant generator terminal voltage. The
generator's terminal voltage is changed by adjusting the
regulator's reference set point.
ENGINE
This standby generator incorporates a Perkins 404D-22
Tier 4 diesel engine. This engine is designed to meet every
performance requirement for the generator. Refer to Table 2
for engine specifications.
In keeping with Multiquip’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
ELECTRONIC GOVERNOR SYSTEM
The electronic governor system controls the RPMs of the
engine. When the engine demand increases or decreases,
the governor system regulates the frequency variation to
± 0.25%.
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 17
MAJOR COMPONENTS
2
1
3
4
5
6
7
13
14
9
8
10
11
12
Figure 3. Major Components
Table 4. Generator Major Components
ITEM NO. DESCRIPTION
1 Housing Assembly
PAGE 18 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
2 Exhaust Rain Cap
3 Camlok Connector Box Assembly
4 Fuel System Sub Base Assembly
5 Door Assembly
6 Generator Assembly
7 Circuit Breaker Assembly
8 Battery Assembly
9 Jacket Water Heater Assembly
10 Battery Charger Assembly
11 Starter Solenoid
12 Engine Assembly
13 Controller Assembly
14 Glow Plug Relay
BASIC ENGINE COMPONENTS
6
1
5
4
12
2
11
7
3
8
Figure 4. Basic Engine Components
Table 5. Basic Engine Components
ITEM NO. DESCRIPTION
1 Radiator
2 Alternator
3 Starter
4 Air Filter
5 Oil Filler Cap
6 Muffler
7 Fuel Filter
8 Oil Drain Plug
9 Oil Filter
9
10
10 Oil Dipstick
11 Governor Actuator
12 Fuel Injection Pump
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 19
DIGITAL CONTROLLER PANEL
1
3
13
Microprocessor Engine Controller
Vavg
EXIT
RUN OFF
FREQUENCY
ADJUST
600
SILENCE
14
ALARM
SHUTDOWN
2
6
7
15 16
Figure 5. Digital Controller Components
1. Liquid Crystal Display — Displays voltage, amperage,
frequency,engine information, fault warnings, and other
generator and engine information.
2. EXIT Pushbutton — Press button to scroll backwards
through the status menus or programming prompts.
Press and hold for approximately 2 seconds to exit
programming menu when in the programming mode.
3. DECREMENT Pushbutton — Press button to change
a programming value while in the programming
mode. Press and hold this button to decrease value
continuously and release when desired value is
displayed. NOTE: The longer the button is held down,
the faster the value will decrease.
4. INCREMENT Pushbutton — Press button to change
a programming value while in the programming mode
or to select a desired programming menu loop. Press
and hold this button to increase value continuously and
release when desired value is displayed. NOTE: The
longer the button is held down, the faster the value
will increase.
5. ENTER Pushbutton — Press button to scroll through
the status menus or programming prompts. This
button is used to enter a programming mode as well
as accepting changed programming values. NOTE:
The longer the button is held down, the faster the next
menu prompt will appear.
6. RUN Pushbutton and LED — Press button to initiate
a manual start signal to the generator. The LED will
light when in RUN mode.
4
11
MEC 20
Aavg
Freq
508
LAMP TEST
DECREMENT INCREMENT
AUTO
RESET
60.0
ENTER
LOAD
TEST
VOLTAGE
ADJUST
READY
SPEED SIGNAL
EMERGENCY
STOP
12
5
10
9
8
7. OFF Pushbutton and LED — Press button to initiate
a stop signal to the generator. The LED will light when
in OFF mode.
8. AUTO Pushbutton and LED — Press button to initiate
automatic operation of the generator. The LED will light
when in AUTO mode.
9. LOAD TEST Pushbutton and LED — Press button to
initiate load test of the generator when connected to
an associated transfer switch. The LED will light when
in LOAD TEST mode.
10. EMERGENCY STOP Pushbutton and LED — Press
button to initiate an emergency stop signal to the
generator.
11. READY LED — Lights when the generator is set for
automatic operation and no shutdown or alarm faults
have been activated.
12. SPEED SIGNAL LED — Lights when the engine speed
signal is detected.
13. ALARM LED — Lights when any pre-programmed
alarm fault has been activated.
14. SHU TDOWN LE D — Flas hes when any preprogrammed shutdown fault has been activated.
15. FREQUENCY ADJUST — This screwdriver adjustable
potentiometer is used to fine tune the roll-off frequency
from 54 to 61 Hz.
16. VOLTAGE ADJUST — This screwdriver adjustable
potentiometer is used to fine tune the generator output
voltage.
PAGE 20 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
CONNECTOR OUTLET BOX AND MAIN CIRCUIT BREAKER
Ground
Neutral
OUTLET CONNECTORS
The Camlok outlet box has the following connectors
Ground (GRND.)
Neutral (NEUT.)
LEG 1, LEG 2, LEG 3 (3-phase only)
Black
Red
Ground
(Green)
Camlok
Panel
Green
White
Green
Neutral
White
L1
L2
Black
Leg 1
(Black)
(White)
Leg 2
(Red)
Red
MAIN CIRCUIT BREAKER
The generator is equipped with a three-pole, 100 or 30
amp, (single/three phase) circuit breaker to protect the
generator from overload.
See Figure 6 for connections.
Green
White
L1
L2
Circuit
Breaker
100A
Black
Red
Generator
Single Phase
Leg 2
(Red)
Leg 1
(Black)
Leg 3
(Blue)
Neutral
(White)
Red
Black
Ground
Ground
(Green)
Camlok
Panel
Green
White
Green
Neutral
White
Green
White
Black
L1
L2
L3
L1
Blue
L2
Black
L3
Blue
Red
Circuit
Breaker
30A
Blue
Figure 6. Camlok Box and Circuit Breaker Connections
Generator
Red
Three Phase
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 21
LOAD APPLICATION/GENERATOR OUTPUT
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0. See Table 6 below
when connecting loads.
Table 6. Power Factor By Load
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable. Refer to
Table 7 to select the correct cable size.
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generator’s rated output (kW) can be used.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generator's rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generator’s rated output (kW) multiplied by 0.8 can be
used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
a transfer switch. Serious damage to the building’s
electrical system may occur without this transfer switch.
Electronic devices, communication
equipment
Common power tools 0.8
1.0
Generator Amperage
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.
Table 7. Cable Selection (60 Hz, Single Phase Operation)
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
Table 8. Generator Maximum Amps
Rated Voltage Maximum Amps
1Ø 120 Volt 83 X 2 amps (4 wire)
1Ø 240 Volt 83 amps (4 wire)
PAGE 22 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
INSPECTION/SETUP
MAIN CIRCUIT BREAKER
The generator is equipped with a 3-pole, 100-amp circuit
breaker to protect it from overload. Make sure that the circuit
breaker is in the OFF position prior to starting the engine.
LUBRICATION OIL
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator
is level and verify that the oil level is maintained between
the two notches (Figure 7) on the dipstick. See Table 9 for
proper selection of engine oil.
Figure 7. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the
oil drain plug, and refill with the specified amount of oil as
outlined in the Perkins Engine Owner’s Manual. Oil should
be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
FUEL CHECK
DANGER
Fuel spillage on a hot engine can cause
a fire or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refilling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understood this section should refill the fuel tank
system.
This generator has a fuel tank located in the sub base
assembly frame (Figure 3). ALWAYS fill the fuel tank with
clean fresh #2 diesel fuel. DO NOT fill the fuel tank beyond
its capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safe container. If the container does
not have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Refueling Procedure:
WARNING
Table 9. Recommended Motor Oil
CAUTION
ALWAYS make sure generator is on firm level ground
before refueling to prevent spilling and maximize the
amount of fuel that can be pumped into the tank.
MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11) — PAGE 23
Diesel fuel and its vapors are dangerous
to your heal th and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
INSPECTION/SETUP
DO NOT fill on
1. Place the generator level with the ground. Failure to do
so will cause fuel to spill from the tank before reaching
full capacity (Figure 8).
70
unlevel ground
!
!
NOTICE
=
Unlevel Ground
Level Ground
Figure 8. Only Fill on Level Ground
Unlevel Ground
Level Ground
ONLY use #2 diesel fuel when refueling.
2. Unlatch and remove the cabinet door of the generator.
Remove fuel cap and fill tank (Figure 9).
3. Monitor the fuel gauge while filling fuel tank. Stop filling
when the fuel gauge indicates full (Figure 10). DO NOT
wait for fuel to rise in filler neck.
1/2
E F
Figure 10. Full Fuel Tank
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 11).
DIESEL
Figure 9. Fueling the Generator
FUEL
Heat Source
Fuel EXPANDS
when heated
1/2
!
!
Figure 11. Fuel Expansion
E F
PAGE 24 —MQP20P STANDBY GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (11/28/11)
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