MULTIQUIP MQP56 Operation Manual

OPERATION MANUAL
MODEL MQP56
60HZ GENERATOR
Revision #0 (06/14/17)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:
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.
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 3
MQP56 60Hz Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Safety Information .............................................. 5-10
Specifications ........................................................ 11
Dimensions ............................................................ 12
Installation ........................................................ 14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel....................................20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ................................................. 26
Generator Outputs/Gauge Reading ....................... 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Generator Start-Up Procedure ........................ 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance ..................................................... 38-45
Generator Wiring Diagram ..................................... 46
Engine Wiring Diagram .......................................... 47
Troubleshooting (Generator) .................................. 48
Troubleshooting (Diagnostic Lamp) ....................... 49
Battery Charger Wiring Diagram ........................... 50
Jacket Water Heater Wiring Diagram ..................... 51
TABLE OF CONTENTS
PAGE 4 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
SAFETY INFORMATION
DO NOT operate or service the generator before reading the entire manual. Safety precautions should be followed at all times when operating this generator. 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
SAFETY SYMBOLS
Potential hazards associated with the operation of this generator will be referenced with hazard symbols which may appear throughout this manual in conjunction with
safety messages.
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS INJURY.
or NOTICE.
CAUTION
Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 5
SAFETY INFORMATION
GENERAL SAFETY
NEVER use accessories or attachments that are not
recommended by MQ Power for this generator. Damage
Also, know the
and
This information will be invaluable in
emergency or safety devices.
These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these
lubricate components or attempt service on a
keep the generator in proper running condition.
Fix damage to generator and replace any broken parts
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.
CAUTION
NEVER operate this generator 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 generator when not
feeling well due to fatigue, illness or when under medication.
NEVER operate this generator under the infl uence of
drugs or alcohol.
ALWAYS check the generator for loosened threads or bolts before starting.
DO NOT use the generator for any purpose other than
its intended purposes or applications.
to the generator 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
 NEVER operate the generator in an explosive
atmosphere or near combustible materials. An explosion or fi re could result causing severe
bodily harm or even death.
DANGER
WARNING
NOTICE
This generator 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 generator modifi cations. Unauthorized generator modifi cation will void all warranties.
NEVER disconnect any
devices will void all warranties.
CAUTION
 NEVER
running machine.
NOTICE
 ALWAYS ensure generator is on level ground before use.
 ALWAYS
immediately.
 ALWAYS
PAGE 6 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
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 which are operated for extended periods with light or 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 unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce
it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system 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
State Health Safety Codes and Public Resources 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 to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed 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
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 in this generator
requires an adequate free fl ow of cooling air. NEVER operate this generator 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 generator or engine.
WARNING
DO NOT place hands or fingers inside engine
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.
 NEVER
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage to the engine or generator can result if operating in speed ranges above the maximum allowable.
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
to completely burn all of the fuel.
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.
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 generator.
hours to burn off the accumulated unburned fuel.
local Health and Safety Administrator.
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 7
FUEL SAFETY
DANGER
ELECTRICAL SAFETY
 Backfeed to a utility system can cause electrocution
codes. Failure to do so could result in electrical shock or
while AC power from the
cables or cords when
connecting generator to generator. Inspect for cuts in the
connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
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.
SAFETY INFORMATION
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
burn, causing serious injury or even death.
Power Cord/Cable Safety
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 around or near the
generator. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals during operation can cause electrocution,
electrical shock or burn.
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.
DANGER
 NEVER let power cords or cables lay in water.
 NEVER stand in water
generator is being transferred to a load.
NEVER use damaged or worn
insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The possibility exists of electrical shock,
electrocution or death.
 Make sure power cables are securely
damage to the generator.
NOTICE
 ALWAYS
Chart in this manual.
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 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
SAFETY INFORMATION
Grounding Safety
BATTERY SAFETY
keep the battery charged. If the battery is not
recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
If the battery liquid (dilute sulfuric acid) comes into
, rinse skin or clothing
If the battery liquid (dilute sulfuric acid) comes into
, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
NEGATIVE battery terminal
keep battery cables in good working condition.
WARNING
DANGER
This generator is equipped with a grounding terminal attached to the enclosure. Electrical grounding requirements can differ by State, Province, District,
Municipality, and unique application settings.
For portable and vehicle-mounted generators, Multiquip recognizes the guidance provided in NEC Handbook Article 250.34 Parts A and B, and 29 CFR 1926.404 (f) (3) (i). If a more defi nitive earth-to-ground safeguard is required, please consult a qualifi ed electrician and reference appropriate National Electrical Code (NEC) guidelines in establishing an exterior grounding point
generator.
NEVER use gas piping as an electrical ground.
NOTICE
There is a permanent conductor bond between generator (stator winding) and the frame.
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.
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
charged, combustible gas will build up.
 ALWAYS
of combustible gasses.
contact with clothing or skin immediately with plenty of water.
contact with eyes
seek medical attention.
CAUTION
 ALWAYS disconnect the
before performing service on the generator.
 ALWAYS
Repair or replace all worn cables.
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 9
SAFETY INFORMATION
ENVIRONMENTAL SAFETY/DECOMMISSIONING
Decommissioning is a controlled process used to safely retire a piece of generator that is no longer serviceable. If the generator poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain (beyond life-cycle reliability) and is to be decommissioned (demolition and dismantlement),be sure to follow rules below.
EMISSIONS INFORMATION
The diesel engine used in this generator has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained
This engine has been certifi ed to meet US EPA Evaporative
Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the generator or create an unsafe
Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in fi nes or other penalties.
The emission control label is an integral part of the emission
If a replacement emission label is needed, please contact
NOTICE
DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.
Contact your country's Department of
Public Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this generator.
When the life cycle of this generator is over, remove
battery(s) and bring to an appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.
When the life cycle of this generator is over, it is
recommended that the generator frame and all other metal parts be sent to a recycling center.
Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.
NOTICE
in diesel exhaust emissions.
emissions requirements in the installed confi guration.
condition.
Emission Control Label
system and is strictly controlled by regulations.
The label must remain with the engine for its entire life.
your authorized engine distributor.
PAGE 10 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
Table 1. Generator Specifications
Model
Type
Armature Connection Star with Neutral Zigzag
Phase
Standby Output
Prime Output
3Ø Voltage (L-L/L-N)
Voltage Selector Switch at 3Ø 240/139
3Ø Voltage (L-L/L-N)
Voltage Selector Switch at 3Ø 480/277
1Ø Voltage (L-L/L-N)
Voltage Selector Switch at 1Ø 240/120
Power Factor
Frequency
Speed
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Wet Weight
Table 2. Engine Specifications
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Engine Oil Type
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
SPECIFICATIONS
MQP56
Revolving field, self ventilated,
open protected type synchronous generator
3 Single
77 kVA (62 kW) 44 KW
70 kVA (56 KW) 40 KW
208Y/120, 220Y/127,
240Y/139
416Y/240, 440Y/254,
480Y/277
N/A 240/120
0.8 1.0
60 Hz
1800 rpm
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
2,701 lbs. (1,225 kg.)
3,035 lbs. (1,376 kg.)
ISUZU 4JJ1X Tier 3
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
3.76 in. x 4.13 in. (95.4 mm x 105 mm)
3
183 in
( 3.00 liters)
85 HP at 1800 rpm
Electric
3.09 gal. (11.7 liters)
3.96 gal. (15.0 liters)
API service class CJ-4 or JASO DH-2
Ultra Low Sulfer No. 2 Diesel Fuel
40 gal. (150 liters)
4.1 gal. (15.4 L)/hr at full load 3.1 gal. (11.9 L)/hr at 3/4 load
2.2 gal. (8.4 L)/hr at 1/2 load 1.4 gal. (5.2 L)/hr at 1/4 load
12V 72Ah x 1
N/A
N/A
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 11
DIMENSIONS
TOP VIEW
B
A
D
C
E
SIDE VIEW
FRONT VIEW
G
F
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
A 30.3 (770) F 94.5 (2400)
B 30.5 (775) G 55.1 (1400)
C 35.8 (910) H 35.43 (900)
D 30.5 (770)
H
E 35.8 (910)
Dimension in. (mm) Reference Letter Dimension in. (mm)
PAGE 12 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
NOTES
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 13
GENERATOR
./2.4 M (MINIMUM)
GROUND LUG
GROUND CABLE
INSTALLATION
IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD.
REFERENCE
NEC 250
8 FT
Figure 2. Typical Generator Grounding Application
PAGE 14 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
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 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.
GENERATOR GROUNDING
NOTICE
The Occupational Safety and Health Administration (OSHA) and the National Electrical Code (NEC) recommend that if the generator is providing electrical power to a structure (home, office shop, trailer or similar) it must be connected to a grounding electrode system, such a driven ground rod (Figure 2).
if applicable ,to guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground, (Figure 2).
NOTICE
ALWAYS check with State, Province, District and Municipalities for electrical grounding requirements before using generator.
Article 250 (Grounding) of the NEC handbook 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.
INDOOR INSTALLATION
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 set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 54.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.
NEC article 250 specifices the following grounding requirements:
1. Use one of the following wire types to connect the generator to earth ground.
a. Copper 10 AWG (5.3 mm
b. Aluminum 8 AWG (8.4 mm
2
) or larger.
2
) or larger.
2. When grounding of the generator (Figure 2) is required, connect one end the ground cable to the ground lug on the generator. Connect the other end of the ground cable to the ground rod (earth ground).
3. NEC article 250 specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.
MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17) — PAGE 15
GENERAL INFORMATION
GENERATOR
The MQ Power Model MQP56 generator (Figure 3) is a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
 Tachometer  Water Temperature Gauge  Warning Lamp  Pre-Heat Lamp  Oil Pressure Gauge  Charging Ammeter Gauge  Fuel Level Gauge  Panel Light/Panel Light Switch  ECU Controller  Engine Speed Switch
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltmeter Change-Over Switch  Voltage Regulator  3-Pole, 175 amp Main Circuit Breaker  “Control Box” (Located Behind the Gen. Control Panel)
• Automatic Voltage Regulator
• Current Transformer
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
 Three 240/120V output receptacles (CS-6369), 50A  Three auxiliary circuit breakers, 50A  Two 120V output duplex receptacles (GFCI), 20A  Two duplex circuit breakers, 20A  Five output terminal lugs (3Ø power)
OPEN DELTA EXCITATION SYSTEM
This generator is equipped with the state of the art “Open­Delta” excitation system. The open delta system consist
of an electrically independent winding wound among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.
When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.
The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “fixed ceiling” and responds according the demands of the required load.
ENGINE
This generator unit incorporates an ISUZU 4JJ1X diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine specifications.
In keeping with MQ Power’s policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.
PAGE 16 — MQP56 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/14/17)
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