Multiquip MQP60IV manual

© COPYRIGHT 2007, MQ PPOWER MQ POWER APPLICA TION & INST ALLA TION MANUAL Industrial Generator Set Application & Installation Manual Re vision #4 (09/07/07) P ARTS DEP ARTMENT : 800-427-1244 F A X: 800-637-3284 SER VICE DEP ARTMENT : 800-835-2551 F AX: 310-638-8046 MQPO WER A Division of Multiquip Inc. POST OFFICE BO X 6254 CARSON, CA 9074[...]

P A GE 2 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07)[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 3 HERE'S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING MUL TIQUIP’S MAIN PHONE NUMBERS 800-421-1244 FAX: 310-537-3927 310-537-3700 PAR TS DEP AR TMENT 800-427-1244 FAX: 310-637-3284 310-537-3700 MQ PO WER SER VI[...]

P A GE 4 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) T ABLE OF CONTENTS Proposition 65 Calif or nia W ar ning ............................. 2 Here's How T o Get Help ............................................ 3 T able Of Contents ..................................................... 4 [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 5 NO TES P A GE[...]

P A GE 6 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) SAFETY MESSA GE ALERT SYMBOLS Safety precautions should be followed at all times when installing or operating this equipment. F ailure to read and understand the Safety Messages and Installation Instructions could result in injury to yourse[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 7 SAFETY MESSA GE ALERT SYMBOLS Accidental Starting AL W A YS place the ignition switch or genset starting device in the OFF position, remove key and/or disconnect the battery before servicing the engine or equipment. Over Speed Conditions NEVER tamp[...]

P A GE 8 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) IMPOR T ANT SAFETY INSTR UCTIONS ■ The engine of this generator requires an adequate free flo w of cooling air . Ne ver operate the gener ator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is res[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 9 IMPOR T ANT SAFETY INSTR UCTIONS ■ NEVER connect the generator to house wiring. This is illegal and very dangerous. Electrical shock could occur causing damage to the generator and bodily harm — even death! ■ NEVER use damaged or worn cables [...]

P A GE 10 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) IMPOR T ANT SAFETY INSTR UCTIONS Operation Safety ■ AL W A YS be sure the operator is f amiliar with proper safety precautions and operations techniques before using generator . ■ DO NO T allow unauthorized people near equipment. ■ A[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 11 Battery Safety The battery is a major component of the engine-generator set. The genset will not star t without a properly maintained batter y . Disconnecting the batter y pre vents the engine from star ting. Alwa ys obser ve the f ollowing saf et[...]

P A GE 12 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) IMPOR T ANT SAFETY INSTRUCTIONS Fire Protection The design, selection, and installation of fire protection systems is beyond the scope of this manual because of the wide range of f actors to consider . In general, e very possible measure s[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 13 T ranspor ting ■ Alwa ys shutdown engine bef ore tr ansporting. ■ Ne v er tr anspor t generator with air intak e doors open. ■ Tighten fuel tank cap securely . ■ Drain fuel when transpor ting generator ov er long distances or bad roads. ?[...]

P A GE 14 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) INTRODUCTION Introduction Engine-Generator sets provide emergency power in the event of utility power failure, provide power where utility power is not available and can provide an alternative power means in areas where utility power may b[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 15 Overview These installation recommendations apply to typical installations with standard model gensets. Whene ver possible, these recommendations also cover factory designed options or modifications. Ho we ver , because of the large amount of vari[...]

P A GE 16 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) INST ALLA TION O VER VIEW Cold Climates and Derating Factors Extreme temperature and high elevation effect the efficiency of the engine-generator set. Always take into account derating factors of climate and elevation when sizing a generat[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 17 GENSET SIZING Generator Set Sizing Calculations The generator set must be sized to supply the maximum star ting (power surge) demands and the steady-state running loads of the connected equipment. It is impor tant to ha v e the correct generator t[...]

P A GE 18 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) GENSET SIZING Generator Set Sizing Calculations (Continued) Step 2. Create a Generator Set W orksheet a . When creating a worksheet, number a worksheet for each sequenced load step . The number b loc k is in the upper r ight hand corner of[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 19 GENSET SIZING Figure 1. Genset Sizing W orksheets (Example T wo-Step Loading Application) NOTES: a. F or the two 100 HP motors , SkV A = HP x NEMA Code Letter Multiplier (T able 6) = 100 x 5.9 x 0.64 = 377.6 b. SkW = SkV A x SPF = 377.6 x 0.3 =113[...]

P A GE 20 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) GENSET SIZING Generator Set Sizing Calculations (Continued) Step 3. Enter Individual Load Characteristics a. Calculate the values f or SkV A, SkW , RkV A, and RkW and then enter the values on the worksheets. See determining load characteri[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 21 GENSET SIZING Generator Set Sizing Calculations (Continued) Step 5. Select a Generator Set a. Establish the minimum size required i . At this point the addition of future loads should be considered. The RkW and RkV A values that were highlighted o[...]

P A GE 22 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) GENSET SIZING — DETERMINING LO AD CHARA CTERISTICS Determining Load Characteristics Lighting For all types of lighting loads: RkW = The sum of the rated w atts of all lamps and ballasts. T ypical ballast wattages are defined by T ab le 2[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 23 GENSET SIZING — DETERMINING LO AD CHARA CTERISTICS Three-Phase Induction Motors Calculate RkW as follows: If EFF (motor running efficiency) of the motor is not known, ref er to T able 5 and use the v alue corresponding to the motor horsepower . [...]

P A GE 24 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) GENSET SIZING — DETERMINING LO AD CHARA CTERISTICS Determining Load Characteristics (continued) 5. If reduced v oltage motor star ting is used, determine SkV A as in Steps 1, 2, 3, or 4 on previous page , and then multiply the value by t[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 25 GENSET SIZING — DETERMINING LO AD CHARA CTERISTICS F P R d n a , F F E , F P S , A V k S r o t o M e s a h P e e r h T . 7 e l b a T P H s r e t t e L e d o C r o t o M A M E Ns r o t c a F r o t o M AB C D E F G H J K L N F P SF F EF P R 4 / 15[...]

P A GE 26 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) GENSET SIZING — DETERMINING LO AD CHARA CTERISTICS Synchronous Motors Although star ting requirements for synchronous motors are low er , it is recommended to deter mine star ting requirements in the same manner as induction motors previ[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 27 ENVIRONMENT AL CONSIDERA TIONS — dB(A) Noise Consideration Because noise effects the surrounding environment, it is impor tant to consider noise factors when installing a genset. The following is a brief approach to evaluating noise sources and [...]

P A GE 28 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) ENVIR ONMENT AL CONSIDERA TIONS — dB(A) Figure 2. dB(A) Comparison Chart Comparison Chart dB(A) Figure 2 below provides a comparison of dB(A) levels for daily noises and the typical range of generator sets. Open generator sets are unhous[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 29 ENVIR ONMENT AL CONSIDERA TIONS — dB(A) Adding Additional Sound Sources The noise level at a given location is the sum of the noise levels from all sources, including reflecting sources. For example, the noise level in a free field along side of[...]

P A GE 30 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) ENVIR ONMENT AL CONSIDERA TIONS — dB(A) Effects of Distance As the distance between a noise source and receiver increases, the sound level decreases. If a second sound measurement is taken twice as far from the source, the second reading[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 31 ENVIR ONMENT AL CONSIDERA TIONS — dB(A) Reducing Noise Structure-Borne Noise Structure-borne noise is transmitted or generated as vibrations in structures. Vibrating structures create sound pressure wa ves (noise) in the surrounding air . Connec[...]

P A GE 32 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) ENVIR ONMENT AL CONSIDERA TIONS — dB(A) Acoustic Material Consider the following when selecting acoustic material: 1. DO NO T use fiberglass as an acoustic mater ial. Fiberglass is a poor selection of acoustic material because of its low[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 33 Mounting Mounting the generator set is a critical par t of the installation. A proper f oundation must be ab le to suppor t the weight of the generator set and its accessories, resist dynamic loads, and not transmit excessive noise and vibration. [...]

P A GE 34 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MOUNTING FOUND A TION Mounting Foundation Figure 6 below shows the typical foundation installation. Figure 7 below shows the typical footing on a foundation in soil with a low load bearing capacity . Figure 7. T ypical Footing Figure 6. T [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 35 MOUNTING THE GENERA T OR SET General Information Generator set installations must be engineered so the generator set will function properly under the expected load conditions. Use these instructions as a general guide only . Follow the instruction[...]

P A GE 36 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MOUNTING — VIBRA TION ISOLA T ORS Vibration Isolators Installation and Adjustment Procedure 1. Place the vibration isolators on the genset suppor t structure. The isolators should be shimmed or grouted to ensure that all of the isolator [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 37 MECHANICAL INST ALLA TION — FUEL SYSTEM (DIESEL) MECHANICAL CONNECTIONS Introduction After considering all applicable codes and laws and finding a suitable location site for the generator set, the installer should consider the mechanical connect[...]

P A GE 38 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — FUEL SYSTEM (DIESEL) Subbase T ank Base mounted or subbase fuel tanks are used to store fuel directly underneath the engine-generator set, eliminating the need for a remote main fuel supply tank and/or auxilia[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 39 MECHANICAL INST ALLA TION — FUEL SYSTEM (DIESEL) Diesel Fuel Supply Consider the following when installing a diesel fuel supply system:  Fuel supply tank construction, location, installation, venting, piping, testing, and inspection must comp[...]

P A GE 40 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS) Gaseous Fuels Some MQ P o wer Industrial generator sets may utiliz e gaseous fuels such as Pipeline natural gas or Liquid P etroleum Gas (LPG). Regardless of the fuel used, the prim[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 41 MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS) Gaseous Fuel Supply Consider the following when installing a natural gas or LPG fuel system:  Gaseous fuel supply system design, materials, components, f abr ication, assembly , installa[...]

P A GE 42 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) T ABLE 12. NA TURAL GAS SCHED ULE 40 IR ON PIPE SIZIN G Pipe Size (in.) Length (ft.) 1/4 (0.3 64) 3/8 (0.4 93) 1/2 (0.622) 3/ 4 (0.824) 1 (1.049) 1 1/4 (1.380) 1 1/2 (1.610) 2 (2.067) 2 1/2 (2.4 69) 3 (3.068) 4 (4.026) Maximum Cap acity in[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 43 MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS) T A BLE 14. PROP ANE V APOR SCHEDULE 40 IRON PIPE SIZING Pipe Size (in.) Length (ft.) 1/2 (0.622) 3/4 (0.824) 1 (1.049) 1 1/4 (1.38) 1 1/2 (1.61) 2 (2.067) 3 (3.068) 3 1/ 2 (3.548) 4 (4.026[...]

P A GE 44 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — FUEL SYSTEM T A BLE 16. L IQUID PROP ANE SCHEDULE 40 IR ON PIP E SIZING Length of Pipe, ft. Pipe Size, in. 1/2 (0.622) 3/4 (0.824) 1 (1.049 ) 1 1/ 4 (1.38) 1 1/2 (1.61) 2 (2.067) 3 (3.068) 3 1/2 (3.548) 4 (4.0[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 45 Fuel Storage Regulations Use e xtreme care when using, transpor ting, and stor ing fuel. Every measure should be taken to protect personnel and the environment from the dangers of fuel. Fuel supply tank design and installation in Nor th Amer ica i[...]

P A GE 46 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — EXHA UST SYSTEM Exhaust System Installation A proper exhaust system installation will ensure safe working conditions and maximum engine efficiency . All MQ P ower- MQP Series, standby , engine-generators hav e[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 47 DO NO T use fle xible tubing to f or m bends or to compensate for misaligned piping.  Reduce corrosion from condensation by installing the muffler as close as practical to the engine.  Suppor t mufflers and piping b y non-combustib le hanger[...]

P A GE 48 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — EXHA UST SYSTEM Exhaust pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. Shield or insulate exhaust pipes if there is danger of personal contact or[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 49 MECHANICAL INST ALLA TION — EXHA UST SYSTEM Exhaust System Installation Reference Data The f ollowing T ables are pro vided f or ref erence when installing the exhaust system. T able 19. Equivalent Length s of Pipe Fittings (Feet) T yp e of Fitt[...]

P A GE 50 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — B A TTER Y SYSTEM Purpose of the Battery The major function of the battery is to supply current to star t the engine . The current required to crank the genset engine varies by model. Cranking current is depen[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 51 MECHANICAL INST ALLA TION — B A TTER Y SYSTEM Engine Starting System Batter y Star ting Systems Batter y star ting systems for gener ator sets are 12 volt or 24 v olt DC (Figure 16). When installing a battery system to star t a generator set, co[...]

P A GE 52 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — NEW B A TTER Y New Battery Installation Bef ore handling a batter y , ref er to page 11 for batter y saf ety instructions . Replacement batteries should equal or exceed the specified battery ratings. Replacing[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 53 MECHANICAL INST ALLA TION — NEW B A TTER Y Dry Charged Batteries (continued) After electrolyte is added, check the open circuit terminal v oltage of the batter y . If a 12-v olt batter y reads less than 10 volts, this is an indication of either [...]

P A GE 54 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) B A TTER Y SYSTEM — TESTING B A TTER Y Batter y T esting Before conducting any battery tests, refer to page 11 for battery safety instructions . Low water-loss batteries of the latest design may incorporate flame-arrester vents to reduce[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 55 B A TTER Y SYSTEM — B A TTER Y TESTING CHART Figure 18. Batter y T esting Chart[...]

P A GE 56 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) B A TTER Y SYSTEM — CHARGING B A TTER Y Charging Lo w W ater -loss Batteries Bef ore charging the batter y , ref er to page 11 f or batter y saf ety instructions . Do not allow untrained personnel charge a battery until they have been th[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 57 Battery Charger Introduction The following section will cover the optional battery chargers off ered f or Industr ial Generators with 12 or 24 V olt systems . MQ P ow er batter y chargers offer accur ate, completely automatic charging of lead-acid[...]

P A GE 58 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) FC & FCA Battery Charger In addition to the LC batter y charger , a v a riation of full featured batter y chargers are offered. The FC & FCA batter y chargers have all of the standard features previously listed, and also include th[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 59 Battery Charger Safety The following safety precautions should always be used with MQ P o w er batter y chargers. z DO NO T oper ate if batter y charger is dropped or otherwise damaged. z DO NO T e xpose charger to rain or sno w . z DO NO T disass[...]

P A GE 60 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) MECHANICAL INST ALLA TION — VENTILA TION AND COOLING Engine Cooling Liquid-cooled engines are cooled by pumping coolant ( a mixture of water and antifreeze) through passages in the engine cylinder block and heads by means of an engine- d[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 61 For outdoor installations, weather and silenced housings are av ailable f or the industr ial generator . Housed industr ial units typically do not use v entilation louv ers . Howe v er , louvers are another ventilation option and can be found on M[...]

P A GE 62 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) F actor y Mounted Radiator V entilation V entilation of the generator set is necessar y to remov e the heat and fumes dissipated b y the engine, generator , batter y , and its accessories as well as provide comb ustion air . When the gense[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 63 MECHANICAL INST ALLA TION — MOUNTED RADIA T OR COOLING Mounted Radiator Cooling System A generator set with a factory-mounted radiator is an integral cooling and v entilating system. This is the recommended configuration involving the least amou[...]

P A GE 64 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) Remote Radiator Cooling (optional) Remote radiator cooling substitutes a remote mounted radiator and an electrically driven fan for the set mounted components (see Figure 27 on next page). Removal of the radiator and the fan from the set r[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 65 MECHANICAL INST ALLA TION — REMO TE RADIA T OR COOLING Figure 27. Remote Radiator Installation Remote Radiator Cooling Figure 27 below shows a typical installation of a remote radiator type cooling system. The coolant flow is provided by the eng[...]

P A GE 66 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) Figure 28. Hot W ell Installation Hot W ell Installation Figure 28 below shows a typical installation of a remote radiator with a hot well cooling system. A remote radiator with a hot well can be used if the elevation of the radiator above[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 67 MECHANICAL INST ALLA TION — HEA T EXCHANGER COOLING Heat Exchanger A heat exchanger installation uses a shell and tube type heat exchanger instead of the standard radiator and fan (see Figure 29 below). Engine jacket and coolant circulates throu[...]

P A GE 68 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) COOLANT TREA TMENT Coolant T reatment Antifreeze (ethylene or propylene glycol base) and water are mixed to lower the freezing point of the cooling system and to raise the boiling point. Ref er to T ab le 24 to deter mine the concentration[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 69 ELECTRICAL INST ALLA TION — DC CONTROL WIRING Contr ol Wiring The genset control box is located either on top or on the side of the alternator housing (see Figure 30 below). It contains connection points for remote control and monitor options wh[...]

P A GE 70 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) Figure 31. T ypical Inner Control Bo x Panel DC CONTR OL WIRING — CONTR OL BO X B A CK P ANEL Control Box The control box contains the following:      Digital Control Module There are several digital control modules availa[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 71 DC CONTR OL WIRING — CONTR OL BO X B A CK P ANEL L1 L2 L3 (3 PH) L1 L2 L3 (3 PH) USE COPPER WIRE ONL Y , MINIMUM SIZE 4 A WG TORQUE TO 120 LB - IN Figure 32. Wiring T erminal Information Figure 33. Wire T emperature Rating T E M P E RA T URE RA [...]

P A GE 72 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) DC CONTR OL WIRING — CONTROL BO X BA CK P ANEL Figure 34. Generator Set Wire Diagram[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 73 A C ELECTRICAL CONNECTIONS Overview This section provides the procedure that is used to connect the AC electrical system of the Industrial generator set. As with all servicing, disconnect the battery charger and the battery cables (negative [-] fi[...]

P A GE 74 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) A C ELECTRICAL CONNECTIONS Emergency Standby Gener ator Systems (600 V olts and below) The National Electric Code (NEC) requires the engine-generator be provided with phase overcurrent protection such as fuses or circuit breakers. In some [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 75 Electrical T erminations Most engine-generators, whether located indoor or outdoors are usually mounted on a concrete pad and typical electrical terminations are brought up underneath the engine-generator f or final ter mination. This cable entry [...]

P A GE 76 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) A C WIRING Generator V oltage Connections The generator output voltage and maximum current rating are specified on the generator set nameplate. Line-to-neutral voltage is always the lower voltage shown and the line-to- line voltage is the [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 77 A C ELECTRICAL CONNECTIONS — SYSTEM GROUNDING System Grounding (continued) Figure 36 below illustrates a typical system grounding for a 3-pole and 4-pole A utomatic T ransf er Switch (A TS). 3-P ole A TS In the 3-pole A TS, note the gener ator n[...]

P A GE 78 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) Equipment Grounding Equipment grounding is the bonding together and grounding of all noncurrent carrying (during normal operation) metallic conduit, equipment enclosures, generator frame, etc. Equipment grounding provides a permanent, cont[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 79 ELECTRICAL DISTRIBUTION SYSTEM Figure 38. T ypical Electrical Distribution System Electrical Distribution System Figure 38 below is a one-line diagram of a typical electrical distribution system that incorporates an emergency generator set.[...]

P A GE 80 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) General Bef ore attempting the initial star t of the generator set, be sure it is ser viced and ready for oper ation. P erform the following: Battery Connections Refer to Battery Safety Section on page 11. The battery cables are supplied w[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 81 Run the Generator Set The final check is to observe the drive belt when the engine is running. 1. Open the generator main line A C cir cuit breaker . - When star ting the engine for the first time after completing the generator set site installati[...]

P A GE 82 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — INST ALLA TION CHECKLIST INST ALLA TION CHECKLIST General  Genset wattage capacity is sufficient to handle maximum anticipated load.  At least three (3) feet of clearance is provide around entire genset for servicing and[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 83 APPENDIX — MAIN-LINE CIRCUIT BREAKER T ABLE 25. F ACT OR Y RECOMM ENDED MAIN LINE CIRCUIT BREAKERS FOR MQ PO WER INDUSTRIAL GENERA TORS Generator Model ABB or Cutle r Hammer Model No. Generator Output (V oltag e) Generator Output (Amp s) Breaker[...]

P A GE 84 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — MAIN-LINE CIRCUIT BREAKER T ABLE 25 . F A CTOR Y RECOMMENDED MAIN LINE CIRCUIT BR EAKERS FOR MQ POWER INDUSTRIAL GENERA T O RS (c ont.) Generator Model ABB o r Cutle r Ham mer Model No. Generator Output (V oltag e) Generator O[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 85 APPENDIX — GENERA T OR SPECIFICA TIONS T ABLE 26. MQ PO WER INDUSTRI AL GENERA T O R SPECIFICA TIONS Generator Model M QP20IZ M QP30DZ MQP30GM M QP40IZ MQP45GM MQP50IZ MQP60GM MQP60IV Standby P ower Output Rating 20 kW (25 kV A ) 30 kW (37.5 kV [...]

P A GE 86 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — GENERA T OR SPECIFICA TIONS T ABLE 26. MQ PO WER INDUSTRIAL GEN ERA TOR SPECIFICA TIONS (cont.) GENERA TOR MQP80GM MQP80IV MQP100GM MQP100IV MQP125IV MQP150IV MQP175IV MQP200IV Standby P ower Output Rating 75 kW (93.75 kV A ) [...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 87 APPENDIX — GENERA T OR SPECIFICA TIONS T ABLE 26. MQ PO WER INDUSTRIAL GENERA TOR SPECIFICA TIONS (cont.) GENERA T OR M QP250IV* MQP300IV M QP350IV M QP400I V* MQP450V O MQP500VO MQP550V O MQP600 V O Standby P ower Output Rati ng 250 kW (312.5 k[...]

P A GE 88 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — ENGINE SPECIFICA TIONS T ABLE 27. MQ POW ER INDUSTRIAL GENERA T OR DIESEL ENGINE SPECIFICA TIONS GENERA TO R MODE L MQP20IZ M QP30DZ MQP40 IZ MQP5 0IZ MQP6 0IV MQP80IV Dies el Engin e Model Isuzu 4LE1PV02 De utz TD 2009 L 4 Is[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 89 APPENDIX — ENGINE SPECIFICA TIONS T ABLE 27. MQ PO WER INDUSTR IAL GENERA T OR DIESEL ENGINE SPECIFICA TIONS (CONT .) GENER A TOR MOD EL MQP1 00IV MQP125IV MQP150IV MQP 175IV MQP200IV MQP250IV Dies el Engine M odel Iveco Motors NEF45 TM2 Iveco M[...]

P A GE 90 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — ENGINE SPECIFICA TIONS T ABLE 27. MQ PO WER INDUSTRIAL GENERA T OR DIESEL ENGINE SPEC IFICA TIONS (C ONT . ) GENERA TOR MODEL MQP3 00IV MQP35 0IV MQP40 0IV MQP 450V O MQP 500VO MQP550 IV Diese l En gine M odel Iveco Mo tors Cu[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 91 APPENDIX — ENGINE SPECIFICA TIONS T ABLE 28. MQ PO WER INDUSTRIAL G ENERA T O R GASEOUS FUEL ENG INE SPECIFICA TIONS GENER A TOR MODEL MQP 30GM MQP45GM MQ P60GM MQP8 0GM MQP100 GM Dies el Engin e Model General M otors V or tec 3000 General Motor[...]

P A GE 92 — INDUSTRIAL GENERA TOR SETS — APPLICA TION & INST ALLA TION MANU AL — REV . #4 (09/07/07) APPENDIX — DIMENSIONS AND WEIGHTS T ABLE 29. MQ PO WER GENERA T OR DIME NSIONS & WEIGHTS GENERA TOR M QP20IZ MQP30DZ MQP30GM MQP40IZ MQP45G M MQP50IZ MQP60GM MQ P60IV MQP80 GM MQP80IV MQP100 GM MQP1 00IV Open Un it with Skid-mount ba[...]

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 93 APPENDIX — DIMENSIONS AND WEIGHTS T ABLE 29. MQ PO WER GENERA TO R DIMENSIONS & WEIGHTS (cont.) GENERA TOR MQP125IV MQP150IV MQP17 5IV MQP200IV MQP250IV** M QP300IV MQP350IV MQP400I V** MQP450VO MQP500V O MQP550V O MQP600V O Open Uni t with [...]

P AR TS AND OPERA TION MANUAL P ARTS DEP ARTMENT : 800-427-1244 F AX: 800-637-3284 SER VICE DEP ARTMENT : 800-835-2551 F AX: 310-638-8046 MQPO WER A Division of Multiquip Inc. POST OFFICE BO X 6254 CARSON, CA 90749 310-537-3700 • 800-883-2551 F AX: 310-632-2656 E-MAIL: mqpower@multiquip.com WWW: www .mqpower .com APPLICA TION & INST ALLA TION[...]