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MULTIQUIP WHISPERWATT Series - User Manual

MULTIQUIP WHISPERWATT Series
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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
WHISPERWATT™ SERIES
MODEL
DCA400SSI4F
DCA400SSI4F3
60 Hz GENERATOR
(ISUZU BQ-6WG1X DIESEL ENGINE)
INSTRUCTION MANUAL NO. C3844302104 (DCA400SSI4F)
INSTRUCTION MANUAL NO. C3844303224A (DCA400SSI4F3)
Revision #3 (04/18/22)
OPERATION MANUAL
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Summary

Proposition 65 Warning

Safety Decals and Placement

Decal Identification and Maintenance

Details the location of safety decals on the generator and advises on keeping them clean and visible.

Understanding Safety Messages and Symbols

Safety Message Levels Explained

Explains the DANGER, WARNING, CAUTION, and NOTICE levels for potential hazards.

Common Safety Hazard Symbols

Lists and defines common hazard symbols used throughout the manual.

General and Generator Operation Safety

General Safety Precautions

Covers protective gear, operator condition, and general safe practices.

Generator Operational Safety Guidelines

Outlines critical safety practices for operating the generator.

Engine Safety and Hazard Awareness

Engine Exhaust Hazards and Ventilation

Warns about carbon monoxide from exhaust and the need for adequate ventilation.

Engine Moving Parts and Hot Surfaces

Advises caution around moving parts and hot components to prevent injury.

Fuel Handling and Towing Safety

Safe Fuel Handling and Storage

Details safe practices for refueling, fuel storage, and fire prevention.

Generator Towing Safety Guidelines

Provides safety recommendations for transporting the generator via trailer.

Electrical and Battery Safety

Electrical Output Terminal Safety

Warns against touching output terminals during operation to prevent electrocution.

Power Cord and Cable Safety

Covers safe use, inspection, and selection of power cords and cables.

Grounding Safety Procedures

Explains proper grounding procedures for electrical safety and compliance.

Battery Handling and Connection Safety

Provides guidelines for safe battery handling, charging, and connection.

Battery, Environmental, and Emissions Safety

Battery Charging and Maintenance

Advises on safe charging practices and maintaining battery fluid levels.

Environmental Safety and Disposal

Covers proper disposal of waste and decommissioning of equipment.

Emissions Control System Information

Details the engine's emission control system and the importance of its label.

Generator and Engine Specifications

Generator Technical Specifications

Lists key technical specifications for the generator models.

Engine Technical Specifications

Provides detailed specifications for the Isuzu diesel engine.

Generator Dimensions

Dimensional Diagrams and Measurements

Shows diagrams with key physical dimensions and reference letters.

Installation Procedures and Grounding

Generator Grounding Connection

Explains how to connect the generator to a suitable earth ground.

Typical Grounding Application Example

Illustrates a typical setup for generator grounding.

Installation Site and Grounding Requirements

Outdoor and Indoor Installation Guidelines

Provides recommendations for generator placement and ventilation.

Generator Grounding Requirements

Details grounding requirements according to NEC and local codes.

Generator Mounting Procedures

Covers proper mounting for stability and alignment.

General Information and Generator Systems

Generator Overview and Design

Describes the generator's purpose and its core design features.

Operating and Control Panel Components

Lists and explains components on the generator's operating and control panels.

Open Delta Excitation System

Explains the generator's excitation system for load capacity.

Engine and Electric Governor Systems

Describes the engine and electric governor system for RPM control.

Extension Cable Selection Guidance

Provides advice on selecting appropriate extension cables for loads.

Paralleling and Load Management Options

Paralleling Option Controller Requirements

Specifies controller requirements for the paralleling option.

Load Sharing Principles (kW and kVAR)

Explains how kW and kVAR loads are shared between generators.

Ethernet Communication for Paralleling

Details Ethernet communication for generator paralleling.

Automatic Load Management

Describes how the generator manages load based on demand.

Paralleling Sequencing and Controller Access

Generator Sequencing and Maintenance Timers

Explains sequencing for maintenance and timer reset procedures.

Controller Password Entry Procedures

Details steps for entering passwords for controller settings.

Parallel Wiring Configurations

Three Phase Parallel Wiring (Camlocks)

Guides on parallel wiring using optional camlock connectors.

3Ø-480 V Parallel Wiring Configuration

Instructions for 3-phase 480V parallel wiring.

3Ø-208 V Parallel Wiring Configuration

Instructions for 3-phase 208V parallel wiring.

Ethernet Cable Connection for Paralleling

Details Ethernet cable connections required for paralleling.

Major Generator Components Identification

Generator Component Diagram

Identifies major components of the generator with a numbered diagram.

Engine Control Unit (ECU 835;845)

ECU 835;845 Controller Functions

Describes the controls and functions of the ECU 835/845 controller.

ECU Display Screen and Indicators

Explains the LCD display and status lamps on the ECU.

ECU Control Buttons and Navigation

Details the functions of the buttons on the ECU controller.

Engine;Generator Control Panel (DCA400 SSI4 F)

ECU 650 Gauge Unit Assembly Functions

Describes the gauges for engine monitoring (oil, temp, voltage, fuel, speed).

Control Panel Indicator Lamps

Explains the meaning of various indicator lamps on the control panel.

Control Panel Meters and Switches

Details the function of meters and switches on the control panel.

DCA400 SSI4 F Control Panel Functions

AC Gauges and Voltage Regulator

Describes AC voltmeter, ammeter, and voltage regulator functions.

Switches and Circuit Breaker Operations

Explains the function of various switches and the main circuit breaker.

Engine;Generator Control Panel (DCA400 SSI4 F3)

ECU 670 Gauge Unit Assembly Functions

Describes gauges for engine, DEF, and load monitoring.

Control Panel Indicator Lamps

Explains the meaning of various indicator lamps on the panel.

Frequency Meter and DEF Gauge

Details frequency meter and DEF level gauge functions.

DCA400 SSI4 F3 Control Panel Functions

AC Gauges and Voltage Regulator

Describes AC voltmeter, ammeter, and voltage regulator functions.

Switches and Circuit Breaker Operations

Explains the function of various switches and the main circuit breaker.

Basler Digital Genset Controller (Option)

DGC-2020 HD Controller Overview

Introduces the Basler DGC-2020HD controller as an optional unit.

Basler DGC-2020 HD Controller Functions

Controller Display and Indicators

Explains the LCD display, LEDs, and indicators on the controller.

Controller Pushbuttons and Mode Selection

Details the functions of controller pushbuttons and mode settings.

Controller Navigation and Editing

Describes menu navigation and setting editing using arrow buttons.

Paralleling Panel (Option) Components

Paralleling Panel Layout and Controls

Identifies components on the paralleling panel with a diagram.

Paralleling Panel Operations

Panel Lights and Voltage Adjustment

Explains panel lighting and the voltage adjustment potentiometer.

Control Power and Emergency Stop

Describes the control power switch and emergency stop button.

Contactor Operation in Manual Mode

Details how to operate contactors for manual generator run.

Output Terminal Panel Familiarization

Output Terminal Panel Layout

Identifies the output terminal panel components and connections.

Terminal Lugs and Receptacle Types

Lists the types of terminal lugs and receptacles available.

Output Terminal Panel Receptacles

120 VAC GFCI Receptacle Testing

Explains how to test and maintain 120V GFCI receptacles.

240;139 V Twist-Lock Receptacle Connections

Details connecting loads to the 240/139V twist-lock receptacles.

Connecting Loads and Overcurrent Protection

Connecting Loads to the Generator

Explains how to connect loads using terminal lugs, receptacles, or camlocks.

Overcurrent Relay and Main Breaker Function

Describes the function of the overcurrent relay and main breaker.

Load Application and Cable Selection

Single-Phase Load Connection Guidelines

Guides connecting single-phase loads and calculating wattage.

Three-Phase Load Power Calculations

Explains how to calculate power requirements for three-phase loads.

Cable Selection Chart and Safety

Offers guidance on selecting cables and safety warnings.

PowerBalance Load Management System

PowerBalance System Description

Explains the optional load management system for engine protection.

How PowerBalance Monitors Load

Details how PowerBalance™ senses and manages engine load.

Generator Output Voltages and Amperage

Voltage Selection via Change-Over Board

Explains selecting output voltages using the voltage change-over board.

Maximum Generator Amperage Ratings

Lists the maximum amperage ratings for different voltages.

Reading Generator Output Gauges

AC Ammeter Gauge Operation

Explains how to read the AC ammeter gauge and its switches.

AC Voltmeter Gauge Operation

Explains how to read the AC voltmeter gauge and its switches.

Output Terminal Panel Connections

3Ø-240 V UVWO Terminal Connections

Details how to connect loads for 3-phase 240V output.

1Ø-240 V UVWO Terminal Connections

Details how to connect loads for single-phase 240V output.

1Ø-120 V UVWO Terminal Connections

Details how to connect loads for single-phase 120V output.

Additional Output Terminal Connections

3Ø-480 V UVWO Terminal Connections

Details how to connect loads for 3-phase 480V output.

1Ø-480 V UVWO Terminal Connections

Details how to connect loads for single-phase 480V output.

1Ø-277 V UVWO Terminal Connections

Details how to connect loads for single-phase 277V output.

Inspection and Setup: Engine Oil

Engine Oil Level Check Procedure

Step-by-step instructions for checking and filling engine oil.

Engine Oil Selection Chart

Recommends SAE oil types based on operating temperature.

Inspection and Setup: Fuel System

Fuel Spill and Fire Hazards

Warns about hazards associated with fuel spillage on hot engines.

Refueling Procedure and Level Tanks

Guides on safe refueling practices and ensuring level ground.

Inspection and Setup: Fuel, Coolant, and DEF

Fuel Tank Filling and Expansion

Advises on proper fuel tank filling and managing fuel expansion.

Coolant Capacity and Freezing Protection

Details coolant capacity and antifreeze for cold weather.

Diesel Exhaust Fluid (DEF) Refueling

Provides instructions for refilling the DEF tank.

Maintenance: Radiator, Air Cleaner, Fan Belt, Battery

Cleaning the Generator Radiator

Instructions for cleaning radiator fins to prevent overheating.

Air Cleaner Inspection and Maintenance

Details inspection and cleaning procedures for the air cleaner.

Fan Belt Tension and Inspection

Guides on checking fan belt tension and inspecting for wear.

Battery Maintenance and Cable Safety

Covers battery maintenance, fluid levels, and cable connection safety.

Battery Connection and System Checks

Battery Connection Safety Precautions

Emphasizes correct battery cable connection and switch positions.

Alternator and Wiring Inspection

Advises inspecting the alternator and electrical wiring for damage.

Piping and Hose Connections Check

Guides on inspecting piping and hoses for leaks and wear.

Generator Start-Up Procedure (Manual)

Before Starting Checks and Switch Positions

Outlines pre-start checks, breaker positions, and switch settings.

Manual Engine Starting Sequence

Step-by-step guide for starting the engine manually.

Manual Start-Up Gauge Readings

Frequency and Voltage Meter Readings

Explains how to interpret frequency and voltage meter readings.

Voltage Adjustment and Ammeter Readings

Details voltage adjustment and ammeter readings under load.

Engine Oil Pressure and Coolant Temperature

Describes how to read engine oil pressure and coolant temperature gauges.

Tachometer Gauge Interpretation

Explains how to read the engine speed (tachometer) gauge.

Generator Start-Up Procedure (Auto Mode)

Auto Mode Breaker Positions and Ammeter

Details breaker positions and ammeter reading in auto mode.

Automatic Start-Up Sequence

Explains the process for starting the generator in auto mode.

Generator Shutdown Procedures

Normal Engine Shutdown Steps

Provides steps for safely shutting down the generator normally.

Emergency Stop Button Usage

Explains when and how to use the emergency stop button.

Automatic Shutdown System Faults

Describes safety devices that automatically shut down the engine.

Maintenance Schedule and Engine Tasks

Inspection and Maintenance Schedule

Outlines recommended maintenance tasks at different hour intervals.

Engine Maintenance Tasks

Lists specific engine maintenance tasks and their frequencies.

Generator Maintenance Tasks

Lists specific generator maintenance tasks.

Air Cleaner Maintenance Procedures

General Inspection and Air Cleaner Cleaning

Guides on general inspection and cleaning air cleaner elements.

Primary and Secondary Air Filter Elements

Details cleaning and replacement procedures for air filter elements.

Air Filter Indicator and Fuel Filter Draining

Air Filter Dust Indicator Function

Explains the air filter dust indicator and filter replacement.

Draining the Fuel Filter Element

Provides instructions for draining water and sediment from the fuel filter.

Fuel Filter and Fuel Pump Maintenance

Fuel Filter Element Replacement

Step-by-step guide for replacing the fuel filter element.

Electromagnetic Fuel Pump Service

Details maintenance for the electromagnetic fuel pump filter.

Fuel Tank and Drive Belt Maintenance

Removing Water from the Fuel Tank

Instructions for draining water and impurities from the fuel tank.

Cleaning Inside the Fuel Tank

Guides on cleaning the inside of the fuel tank.

Drive Belt Tension and Inspection

Guides on checking drive belt tension and inspecting for wear.

Engine Oil and Filter Maintenance

Draining Engine Oil Procedure

Step-by-step instructions for draining and replacing engine oil.

Engine Oil Filter Replacement Procedure

Details the process for replacing the engine oil filter.

Radiator Coolant Maintenance

Draining Engine Coolant Safely

Provides instructions for safely draining engine coolant.

Flushing and Replacing Radiator Coolant

Guides on flushing the radiator and replacing the coolant.

Radiator Exterior Cleaning

Advises on cleaning the radiator exterior with a pressure washer.

Testing GFCI Receptacles

GFCI Receptacle Testing Procedure

Step-by-step guide for testing GFCI receptacles.

GFCI Status LED Interpretation

Explains the meaning of the status LED on GFCI receptacles.

Generator Storage Procedures

Long-Term Generator Storage Recommendations

Provides essential steps for storing the generator for extended periods.

Heater and Battery Charger Options

Engine Block Heater Operation

Explains usage and power requirements for the engine block heater.

Internal Battery Charger Operation

Details how to use the internal battery charger and its power needs.

Emission Control System: DOC

DOC System Function and Purpose

Explains how the Diesel Oxidation Catalyst reduces harmful exhaust gases.

Emission Carbon Check and Cleaning

Advises on checking for and reducing carbon deposition in the exhaust.

Selective Catalytic Reduction (SCR) System

SCR System Function and DEF Usage

Explains how SCR uses DEF to reduce nitrogen oxides in exhaust.

System Purging Guidelines and Safety

Provides safety guidelines for SCR system purging operations.

Diesel Exhaust Fluid (DEF) Level Monitoring

DEF Level System Action Table

Details actions based on DEF tank level and controller messages.

DEF Tank Level Gauge Interpretation

Explains how to read the DEF tank level gauge on the ECU monitor.

DEF Inducement and Warning Levels

DEF Inducement Warning Stages

Outlines the three warning levels for DEF system issues.

Activating Escape Mode

Entering Diagnostic Mode and Status Check

Guides on entering diagnostic mode and checking system status.

Navigating to the Main Menu

Explains how to navigate to the main menu screen.

Escape Mode Operation Procedures

Initiating Escape Mode Request

Details how to send an Escape Mode Request signal to the ECM.

Escape Mode Timer and Resumption

Explains the Escape Mode timer and how operation resumes.

Regeneration and Automatic Shutdown Systems

Manual Regeneration (Basler Controller)

Describes initiating manual regeneration using the Basler controller.

Automatic Shutdown System Faults

Lists conditions that trigger automatic engine shutdown.

Troubleshooting: Diagnostics Mode

Entering Diagnostic Mode

Step-by-step instructions for entering the diagnostic mode.

Fault Diagnostics Modes Explained

Explains the different fault diagnostic modes (DM1, DM2, Last Shutdown).

Troubleshooting: Generator Issues

No Voltage Output Troubleshooting

Identifies possible problems and solutions for no voltage output.

Low and High Voltage Output Troubleshooting

Addresses issues related to low or high voltage output.

Circuit Breaker Tripped Troubleshooting

Provides solutions for circuit breaker tripping issues.

Generator Wiring Diagram (DCA400 SSI4 F)

Generator Wiring Diagram Key

Explains the symbols and labels used in the wiring diagram.

Main Generator and AVR Connections

Details wiring for the main generator armature and AVR.

Controller and Sensor Wiring

Shows wiring connections for the digital controller and sensors.

Engine Wiring Diagram (DCA400 SSI4 F)

Engine Wiring Diagram Key and Color Codes

Explains symbols, wire sizes, and color codes in the engine wiring diagram.

Digital Controller and Power Circuit Wiring

Illustrates wiring for the digital controller and power circuits.

Starter, Fuel, and Sensor Wiring

Details wiring for starter, fuel unit, and sensors.

MCB Sequence Diagram (DCA400 SSI4 F)

MCB Sequence Diagram Key

Explains the symbols and labels used in the MCB sequence diagram.

Circuit Breaker Control Logic

Shows the logic for controlling circuit breakers in the sequence.

Generator Wiring Diagram (DCA400 SSI4 F3)

Generator Wiring Diagram Components

Identifies components and connections in the generator wiring diagram.

AVR and Voltage Change-Over Board Wiring

Details wiring for AVR and voltage change-over board.

Controller and Auxiliary Receptacle Wiring

Shows wiring for the ECU controller and auxiliary receptacles.

Engine Wiring Diagram (DCA400 SSI4 F3)

Engine Wiring Diagram Key and Color Codes

Explains symbols, wire sizes, and color codes in the diagram.

ECU and Control Switch Wiring

Illustrates wiring for the ECU and various control switches.

Starter, Fuel, and Sensor Wiring

Details wiring for starter, fuel unit, and coolant level sensor.

Controller Wiring Diagram (A)

Controller Wiring Diagram Key

Explains the symbols, wire sizes, and color codes used in the diagram.

ECM and Input;Output Connections

Details the connections to the ECM and associated inputs/outputs.

Controller Wiring Diagram (B)

Controller Wiring Diagram Key

Explains the symbols, wire sizes, and color codes used in the diagram.

Dosing Control Unit (DCU) Connections

Details the wiring connections for the Dosing Control Unit (DCU).

Battery Charger Wiring Diagram (Option)

Battery Charger Input and Output Connections

Shows how to connect the battery charger to power and the battery.

Engine Block Heater Wiring Diagram (Option)

Engine Block Heater Power Connections

Details how to connect the engine block heater to a power source.

Getting Help and Support Information

Contact Information for Support

Provides contact details for Multiquip in the US, Canada, and UK.

MULTIQUIP WHISPERWATT Series Specifications

General IconGeneral
CategoryPortable Generator
Fuel TypeDiesel
WeightVarious (depending on model)
DimensionsVarious (depending on model)
Voltage120/240V
EPA CertifiedYes
CARB CompliantYes (for applicable models)

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