: whisper power - Stromgenerator M
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1. Figure 16 Ways to prevent water from getting in December 2014 M GV4 Piccolo for marine applications EN A negative feature of a dry exhaust system is the heat radiated by its components Measures must be taken to overcome the heat problem When a dry exhaust has its outlet on the deck or on the roof of the steering house all the pipes inside the boat has to be insulated THE EXHAUST PIPES WILL BE VERY HOT AND ALL ACCESSIBLE PIPES AND MUFFLERS ARE DANGEROUS TO PEOPLE WHEN NOT INSULATED There are companies that are specialised in insulating hot pipes and fancy systems are available to make it good looking However it is also possible to do it yourself by winding fibreglass or Rockwool around the pipes and seal it with aluminium tape On request Whisper Power can supply insulation jackets for all king of pipes and bents 1 THE STANDARD DRY EXHAUST SYSTEM The standard exhaust system contains On the Genverter o An insulated exhaust bent In the exhaust installation kit ELECTRICAL INSTALLATION 12 VOLT WHEN THE EXHAUST IS LED THROUGH THE SIDE DECK OR ROOF OF THE DECK HOUSE MEASURES HAS TO BE TAKEN TO PREVENT RAINWATER TO ENTER THE SYSTEM SPECIAL RAIN CAPS ARE AVAILABLE AS AN OPTION INSTALLATION OF THE DRY EXHAUST Before determining the location of the Genverter set one has to consider how to get away with the exhaust In wind still conditions a light smell of2. E v FLOW DIRECTION SAILING DIRECTION d EE Tm FLOW DIRECTION Figure 7 Installing water intake THIS SHOULD NOT BE DONE IN THE CASE OF A GV4 Piccolo OR ANY OTHER GENVERTER WHEN SAILING AT HIGHER SPEEDS WATER WILL BE FORCED INTO THE INLET AND YOUR ENGINE WILL OVERFLOW See Figure 7 On motorboats and on sailing boats the water scoop for a GV4 Piccolo should be fitted with the opening faced backwards to prevent water being forced in during sailing Use a sealant when mounting the skin fitting 2 8 5 Water strainer Use an appropriate water strainer with connections of 12 5 mm 1 2 Install the water strainer in a well accessible position refer to Figure 6 ref 6 5 cm above the waterline 2 8 6 Siphon breaker air vent When the point of water injection is below the waterline then when the engine is stopped there is a risk that the cooling water may enter the engine as a result of siphoning To avoid this happening the GV4 Piccolo is designed to accommodate a siphon breaker air vent In the standard delivery of the GV4 Piccolo connections are bypassed Hose of 12 5 mm 1 2 inner diameter should be used If the GV 4 cannot be mounted such that the bottom of the GV 4 is placed above the waterline an air vent must be installed Extend the water hose of the by pass 60 cm above waterline and install an air vent Ideally the air vent should
3. article no description dimensions 40290060 AGM Power 12V 55Ah Absorbed Glass Matt 229 x 138 x 210 mm 22 December 2014 M GV4 Piccolo for marine applications EN 5 DIAGRAMS 8 DRAWINGS 5 1 ELECTRICAL DIAGRAMS F ba i s 8 p TE pa a Kl em WW i V C3 1 eo Ed 230V ac consumers mi ad 3 z mg wl Ca e gt e e ele E ef d e T hal a e E o 1 ke Y p T ATA 7 9 pra KI gt EE AA E O aa A GUT AW l D 8 wal LE d Mi o Ss Figure 26 Electrical control diagram EN M GV4 Piccolo for marine applications December 2014 DIAGRAMS amp DRAWINGS 23 AC output PELI H Du output Input IE z 3 ND ao Remote Panel WP PMG R NID 5 A o a 2 E o ee STARTER z W MOTOR En ch han S E Cobalt H OI E Battery salich BATTERY lew DC all FUEL SR TEMP VALVE o SENSOR Figure 27 Electrical wiring diagram 24 December 2014 M GV4 Piccolo for marine applications EN 5 2 MECHANICAL DRAWINGS 520 EN M GV4 Piccolo for marine applications December 2014 Figure 28 GV4 Piccolo mechanical drawings 25 E Whisper OIGA Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com info whisperpower com
4. Ka e de KA Y N 2 3 O 1 Water level 3 Seacock Figure 10 Super silent exhaust system 2 Water exhaust separator 4 Waterlock 12 December 2014 M GV4 Piccolo for marine applications EN INSTALLATION Only when using an exhaust water separator the exhaust may have a length up to 7 5m after the water gas separator However water traps should be avoided as the fumes still contains water and this should not accumulate in bents refer to Figures 12 and 13 An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emission If the M GV4 Piccolo and the exhaust system have been installed correctly neighbouring boats will not be disturbed by Max length A B 2 5 m 8 ft OK WRONG EN M GV4 Piccolo for marine applications December 2014 outlet noise With the super silent exhaust system GV 4 noises are almost inaudible For optimal noise reduction the sea water outlet from the exhaust water separator centre outlet on the unit should be installed below the water level to eliminate noisy splashing of the effluent sea water The through hull outlet for the exhaust fumes should not direct the fumes directly toward the water surface as this will cause excessive noise refer to Figure 14 Figure 11 Install the water lock close to the generator l Figure 12 Water trap in exhaust system 13
5. AC alternator windings are not grounded The housing of the alternator and all other metal parts are grounded It is necessary that the electric installation in the boat must be protected against insulation failures Methods of protection are subjected to rules that can be different depending on the use of the boat and local standards Experts in this field should be consulted To make a connection between neutral and ground is necessary as part of a specific insulation failure protection system In the GV 4 this connection is NOT made in the factory Do not make this connection without installing this specific insulation protection system 3 7 CABLE For the power cable we recommend the use of 4 wire three phase oil resistant cable with a sufficient cross sectional area One wire for earth is included For long cables it is recommended to apply cables with a larger cross section refer to ISO 13297 annex A ELECTRICAL INSTALLATION 12 VOLT 3 8 TRANSFER SWITCH A power source selector switch much be installed between the PMG box and the vehicle s electrical supply system This switch must ensure that all AC consumers can be switched off at once This switch should also be installed to keep the generating set and land grid power systems separate Transfer switches to switch over from a land line to vehicle or from generating set to inverter should be well designed to switch over all wires including
6. a dry exhaust but other combinations could be supplied on request 1 Inter cooling with water injected a wet exhaust 2 Inter cooling with a dry exhaust 3 Keel cooling with a dry exhaust 4 Keel cooling with a wet exhaust 2 8 2 Inter cooling When applying inter cooling the Genverter should have its own sea water inlet and should not be connected to any other engine systems see Figure 6 A properly installed cooling system is critical to keep engine temperatures within an acceptable range Ensure that the installation complies with the following installation instructions 2 8 3 Raw water supply For raw bubbles The return pipe should never be connected to the check if back pressure is the problem by disconnecting the return line just outside the canopy and draining it in a canister When the engine runs smooth now the return piping has to be changed It could also help to install a second electrical 12V fuel lift pump in the supply line to increase the pressure 2 7 4 Fuel filters A fine fuel filter is installed which requires maintenance advises to install an extra fuel filter water fuel separator near the fuel tank Before starting your generating set for the first time follow the fuel system bleeding procedure in the user manual 2 8 COOLING 2 8 1 General For the cooling of an engine on a boat there are two methods available inter cooling and keel cooling Inter cooling is based EN M GV4 Picc
7. be mounted above the yacht keel centre line i e to minimize the influence of swaying on the water intake Fast motorboats will lay deeper when sailing at large speed non planing and have additional pressure on the water inlet This should be avoided to prevent water from entering into the engine IF THE AIR VENT IS CLOGGED THE WATER HOSES WILL NOT BE VENTED WHEN THE GV 4 HAS STOPPED AND WATER CAN BE FORCED INTO THE ENGINE THIS LEADS TO IMMEDIATE ENGINE PROBLEMS AND EVENTUALLY SEVERE DAMAGE DAMAGE CAUSED BY THE INGRESS OF WATER IN THE ENGINE IS NOT COVERED BY WARRANTY The siphon breaker that is delivered with the Whisper Power siphon breaker installation kit does not require a connection for a hose to drain the little water that could be spilled from the valve If you use another kind of siphon breaker that has a hose connection make sure that the drain should go downwards down directly and that it may not end under water Water must flow out freely and air has to flow in freely as well refer to Figure 8 INSTALLATION 2 9 1 Standard wet exhaust system installation The Genverter wet exhaust system must remain completely independent and separate from the exhaust system of any other engine on board A water lock prevents the Genverter from being flooded by cooling water and should be installed as close to the Genverter as possible The lock must be large enough to hold the entire water volume held in the hose from the
8. exhaust fumes around the boat will not be avoidable To bring the exhaust to the deck or to the top of the deck house gives the best results on noise and smell However when the pipes go through the boat they should be insulated and around the hole in the deck or roof should be a collar to prevent rainwater to leak in Both mufflers could be on the roof or one of them or both could be in the machine room In general it is better to have the mufflers wide apart the resonance muffler close to the Genverter and the absorption muffler on the end of the line A short pipe 30cm should be on the far end after the absorption muffler The absorption muffler has no flow direction and could be mounted both ways The resonance muffler should be mounted according to the indication on the muffler itself connections o Jackets for thermal and sound insulation The mufflers are high quality marine mufflers that are much more effective robust and durable than mufflers made for automotive use EN M GV4 Piccolo for marine applications December 2014 CN The resonance muffler should be fitted according to direction o as flow indicated In the kit are clamps to mo the exhaust pipes to stainless steel bars These bars should be mounted to the structure of the boat It is recommend to use rubber mountings whenever possible However take care that the heat conducted through the brackets will not affect the rubber Refer to Figu
9. possible dumping the water over board separately Keel cooling is almost always combined with a dry exhaust EN M GV4 Piccolo for marine applications December 2014 through hull fitting BECAUS SMALL GAS FLOW OF THE a S VERY IMPORTANT TO KEEP STRICTLY TO THENNSTRUCTIONS ABOVE SOME MUFFLERS AND WATER LOCKS CAUSE TOO HIGH lt YOU ARE ADVISED TO USE A WHISPER POWER INSTALLATION KITS OR CHECK THE BACK PRESSURE REFER TO THE USERS MANUAL TOO HIGH BACK PRESSURE CAUSES THE SYSTEM TO FILL UP WITH WATER THAT AFFECTS THE OUTLET VALVE AND VALVE SEAT 11 INSTALLATION St CN __ O 5 E 3 E 0 1 Exhaust water lock 4 Goose neck Figure 9 Standard exhaust system 2 Exhaust outlet muffler 5 Through hull exhaust outlet 40 mm 3 Exhaust line 40 mm 6 Water level 2 9 2 Super silent exhaust system See Figure 9 If the through hull exhaust outlet has to be unted far from the GV4 Piccalo an exhaust water separator must definitely be installed Total length of the exhaust piping eck water separator is more See Figure 8 In order to redt from Genverter to top of goos than 2 50 m The sea water from the separator must run down to the through hull outlet flooding the engine The exhaust water separator is mounted more than 60 cm above the water level oe Sie _ Dip we NA ae pa 40 mm a el O N A el 2 Z O
10. 47 1 50221252 48 4 50221522 49 2 50221632 TOTAL 40230205 no qty article no 50 1 50222020 51 1 50220063 e Spare parts fuel kit Pos qty article no e e Eran 50 43 G CR e ho fuel hose description 50 B supply dimensions 8 mm M14x1 5 mm M14 8 mm M14 M1660 gr 8 mm M16x1 5 mm 8 mm 10 16 mm 14x20x1 5 mm dimensions 6x8 mm 8x16 mm 46 40230092 Filter for strainer fuel water separator EN M GV4 Piccolo for marine applications December 2014 19 INSTALLATION SPECIFICATIONS WATER INLET KIT Generator cooling water inlet Bypass cooling water in i SYPHON BREAKER KIT 1 2 12 5 mm k WATER INLET KIT 12 5 mm pos _qty article no description 1 1 50230052 Intake strainer 3 4 2 50230042 _ Lever operated ball valve FF 3 4 3 50221016 _ Male hose connection 3 4 x13 4 50221521 _ Hose clamp stainless 12 20 5 _3m 50220055 _ Cool water hose transp spiral 13x19mm 6 _ 50230062 _ Nickel plated brass intake strainer 3 4 7 1 _ 50230067 _ Mounting bracket small water strainer 1158 TOTAL 40230201 WATER INLET KIT 12 5 mm SYPHON BREAKER KIT 12 5 mm pos _qty article no _ description 1 1 _ 50230017 _ Siphon breaker valve 12 5mm 1 2 complete including valve assembly 2 6 50221521 _ Hose clamp stainless 12 20 3 _3m 50220057 _ Cooling water hose warm water 13x21mm 4 2 _ 50221260 _ Hose connector 12
11. 5mm 1 2 TOTAL 40230272 SYPHON BREAKER KIT 12 5 MM 1 2 20 December 2014 M GV4 Piccolo for marine applications EN INSTALLATION SPECIFICATIONS WET EXHAUST KIT According to ABYC recommendations all hose connections must be fitted with two hose clamps Maximum torque hose clamps 12Nm 105 InLbs ss mm re mm em pe e em rm mm mm rm em mm rm rm me Generator exhaust AN Figure 24 Delta exha DELTA EXHAUST KIT 40 mm 1 5 8 pos ON articleno description 22 8 50221504 Hoseclampstainless324Amm gt S 23 3m 40220033 Marineexhausthose40mm 198 24 1 402300933 Waterlock40OmmPelta 25 1 50230038 Bass hullfittinghoseconnection14 40 TOTAL 40230251 DELTA EXHAUST KIT 40 mm DELTA WATER SEPARATOR KIT 40 mm 1 5 8 pos _ qty _ article no _ description 22 8 _ 50221504 _ Hose clamp stainless 32 44 mm 23 _2 5m 40220033 _ Marine exhaust hose 40 mm 1 31 sal 50221015 _ Male hose connection 174 x 40mm 32 1 _ 50230044 _ Lever operated ball valve FF 1 33 1 50230033 _ Brass through hull fitting 1 x 70 34 1 _ 40230197 _ Water gas separator Delta 40 40 40mm 1 TOTAL 40230093 Delta water gas separator kit 40mm OPTIONAL INSTALLATION MATERIALS pos _ qty _ article no _ description 21 a _ 50230087 _ Elbow 90 adapter exhaust hose 22 4 _ 50221504 _ Hose clamp stainless 32 44 mm 27 1 _ 50230113 _ Stra
12. INSTALLATION Figure 13 Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure Do not direct the outlet directly toward the water surface OK Figure 14 Outlet directio 2 10 DRY EXHAUST SYSTEM Figure 15 Dry exhaust systems on boats 2 10 1 General remarks A dry exhaust muffler system should be very effective in silencing exhaust noises when applying the right mufflers However noise could be generated by vibrations in the mufflers and be transferred to the boat Tacit factors like the length of specific pipe sections could cause the noise to be amplified It is very difficult to take these factors into account The standard Whisper Power exhaust kit contains the materials to perform a professional installation In the kit is a stainless steel flexible bellow hose to allow for expansion and to prevent vibrations to be transferred 14 BR Rubbers are supplied to mount the mufflers flexible The insulation jacket for the flexible bellow and the resonance muffler are also very effective in damping vibrations Still it could be that additional measures has to be taken like an extra clamp in a vibrating section of pipe insulation blankets on other parts of the system and possibly even additional mufflers When the exhaust is led through the roof of a boat measures has to be taken to prevent rainwater to enter the system Special rain caps are available as an option
13. Tes00Z0r OU Uu INSTALLATION MANUAL FOR MARINE APPLICATIONS High efficiency 4kW Genverter for marine use WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com V1 December 2014 TABLE OF CONTENTS CONTENTS 1 INTRODUC TION asia ia 4 1 1 Use of THIS un E LTE E 4 1 2 NG a a AA 4 1 3 daf ge Lake Cla E 4 1 4 CHP Combined Heat Power general norris dd 4 2 INSTALLATION ATAT AA AA AA AA AA AA AA 5 2 1 E Ir AAAH 5 2 2 Boele 5 2 3 Protection against dirt water high temperature and weather conditions 5 2 4 Instructions for optimal sound and vibration insulation unu a 5 2 4 1 Further recommendAtONS E 5 2 5 e e ooo O o OO eu wenen Bennen 6 2 5 1 EE AA 6 2 6 COMMONS aro aci 6 2 6 1 A e E II e Pe 6 2 7 A aapaw na AG AA NADA AA ANA AA A 7 2 7 1 PUE a 7 2 7 2 PS IEE A e e o E E E O E OEE EA 8 2 7 3 EE 9 2 7 4 FOS AA AA AA 9 2 8 EIERE 9 2 8 1 2 8 2 2 8 3 2 8 4 2 8 5 2 8 6 2 9 Exhaust system 2 9 1 Standard wet exhaust system installation aanne vssvsnnnsrrsensnnnsrrrenen vennnnserevenensenssensnneesevenenevens 11 2 9 2 Super SIME exhaust SY stem aa NA GANA ATA ANA NAAN 12 2 10 DE EE linia dins 14 2 10 1 CE en 14 3 EEECTRICALINSTACEATION 12 VOET AANGAT NANANA NANANA NN NANA 16 3 1 Motor CON ON SE E 16 3 2 ASAS A e ny TO IEE NOA AAT EE T 16 3 3 Other recommendations and warminge 11 aa 16 3 4 AC power sys
14. aking into consideration the safety guidelines and measures Chapter 2 of the user s manual The information specifications illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press G WARNING During installation and commissioning of the Genverter the Safety Guidelines amp Measures are applicable at all times See chapter 2 of the user s manual WARNING A warning symbol draws attention to special warnings instructions or procedures which if not strictly observed may result in damage or destruction of equipment severe personal injury or loss of life DANGER This danger symbol refers to electric danger and draws attention to special warnings instructions or procedures which if not strictly observed may result in electrical shock which will result in severe personal injury or loss of life WARNING Before working installation on the system read the section safety instructions in the user s notice Whilst every effort is particulars contained manufacturer distributor or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof Keep this manual in a secure place 1 2 VALIDITY OF THIS MANUAL All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the two and three cylinder Genverters delivere
15. be considered 1 Most important is the structure on which the Genverter is placed to be stiff Directly below the base frame the structure should be supported vertically to the trusses of the boat When this is not possible horizontal structures additional provisions refer to rocker cover has to be la clearance Please also note that in spite of the automatic oil pressure switch it is still essential that the oil level is checked regularly 2 3 PROTECTION AGAINST DIRT WATER HIGH TEMPERATURE AND WEATHER CONDITIONS The unit is designed to be mounted inside a boat The Genverter is not suited to mount on deck in the open air to be subjected to bad weathers conditions and salt water spray and rain or snow The best place is a dedicated machine room Also inside the boat the Genverter should be protected against bilge water condensation frost and other conditions that will affect the machinery The air inlet of the engine room must be protected against the ingress of water and it is recommended to fit an air inlet strainer for protection against dirt and dust EN M GV4 Piccolo for marine applications December 2014 should be made sti Figure 1 Y In larger vessels a separate and insulated machine room fon the Genverter will help to damp the noise even further Coy 3 Avoid mounting the generating set in close proximity to thin walls or floors that may cause resonance 4 Sound dampening
16. d by WhisperPower This manual is valid for the following models Part number Description 49002005 M GV4 Piccolo MARINE Refer to the user s manual for identification of the Genverter set For other models see our website www whisperpower eu Me INSTALLATION that 1 3 Besides the parts d with the delivery you need ection 4 4 to install the Genverter Please note that this listing may not be complete as every installation differs from the other Oil is not included in the supply Refer to the user manual for the right specifications 1 4 CHP COMBINED HEAT POWER GENERATION The optimum engine operating temperature is between 80 and 110 Celsius The outgoing oil temperature is about 90 up to 110 C The heat exchanger reduces the temperature of the cooling liquid by 20 C to 25 C The returning cold oil therefore has a minimum temperature of at least approx 65 Celsius This means that the cooling circuit can be used for heating up water or any other medium to almost 100 C optional This can be done with an additional heat exchanger Also it could be useful to use the hot air of the radiator for heating purposes WhisperPower can advise on such applications and supply additional installation parts for CHP December 2014 M GV4 Piccolo for marine applications EN 2 INSTALLATION 2 1 GENERAL To ensure reliability and durability of the equipment it is very important that
17. eed up when largest load step that can occur comes in If not increase no load speed Refer to DDC manual Check if the battery charger of the generating set is working max 14 5 Volt Close the sound shield and check the noise level Stop the Genverter set and check the engine again for leakages of oil fuel or coolant and check the oil level again Installation checklist available on our website www whisperpower com Commissioning form available on our website www whisperpower com 4 3 TECHNICAL DATA Refer to the M GV 4 Piccolo User Manual for an overview of general technical specifications December 2014 M GV4 Piccolo for marine applications EN 4 4 SPECIFICATION OF THE ACCESSORIES Water scoop Inlet valve Water strainer Anti siphoning valve Inlet suction hose Exhaust hose in out Water lock Water gas separator Starter battery Fuel filter water separator Fuel inlet and return min 1 2 recommended 3 4 INSTALLATION SPECIFICATIONS min 1 2 in 12 5 mm out recommended 3 4 in 12 5 mm out 12 5 mmin 12 5 mm out 12 5 mm 12 5 mm B40 mm 1 5 8 B40 mm 1 5 8 40 mm 1 5 8 55 Ah 30 micron 8 mm 4 5 INSTALLATION MATERIALS FUEL KIT ama ia S Generator fuel un ak otis ee m Generator fuelout bam Figure 22 Fuel supply kit no qty article no 41 2 50221203 42 1 40230090 43 2 50221618 44 2 50221644 45 2 50221615 46 2 50221616
18. et see Figure 3 The maximum suction height is 1 m If the pump has to lift the fuel higher than one meter an external fuel lift pump must be installed Art No 50201062 When using a second electric fuel supply pump it is recommended to mount a loose supplied pump close to the tank and mount it in an angle or vertical to prevent air bubbles to block the system The pump makes clicking noises and therefore could be mounted on rubber mountings When the clicking noises of the pump are not acceptable another noiseless pump is available as an option Art No 50202200 Figure 3 Fuel supply fuel tank is below the Genverter A Figure 4 Fuel supply fuel tank is above the Genverter Figure 5 Fuel line assembly with fuel lift pump mounted vertically or in an angle gt P ke Ee af k E 4 7 1 Fuel lift pump BT sa la J NG Se a i Y g C i saec n ee ee rr 8 go _ ma JL e K S a ka e 4 aQ e Fuel lift pump 7 d fe mi fe Nik 8 December 2014 M GV4 Piccolo for marine applications EN 2 7 3 Fuel pipes When the tank is above the generating set Figure 4 WhisperPowe
19. ight coupling Delta 40mm 28 1 50230112 Elbow 45 Delta 40mm EN M GV4 Piccolo for marine applications December 2014 21 INSTALLATION SPECIFICATIONS DRY EXHAUST KIT 79 D UITLAATKIT oj 1 69 EXHAUST KIT Figure 25 Dry exhaust kit DRY EXHAUST KIT 1 no qty _ article no _ description 61 A _ST _ 50220041 _ Exhaust hose 500mm SS male female 1 62 1 SI 50220042 _Insul blanket 35x60 exhaust hose 1 1 2 63 ae SI 50230520 _ Absorption muffler steel 1 64 1 ST 50230521 _ Resonance muffler steel 1 65 A _ST 50230522 _ Insulation blanket R muffler 1 66 2 ST 50221401 _ Pipe nipple 1 x300mm galvanised 67 2 ST 50221421 _ Parallel male coupling 1 galvanised 68 2 o ST 50221411 _ Straight coupling f f 1 galvanised 69 E _ST 50221661 _Ukclamp samping 703 S mee Seet U clamp 25c M in passivated 3 np ST 50211406 Washer SP MIO Po 2 6 STN 5021144 ams J OO 7 73 6 ST 50211466 _ Nut hexak a 75 1 ST 50221471 Elbow 90 degr m f galvanised 1 BATTERY INSTALLATION KIT article no _ description _ dimensions 61112002 _ WBC Handy 20 charger 12V 2A _157 x 33 x 34 mm 40290093 _ battery terminal NEG 40290094 battery terminal POS 40290099 _ M8 battery pole adapter set 40290098 isolation caps red amp black 502144701 WP Compact Manual Battery Switch 300A 72x72x78 mm 40290106 INSTALLATION KIT FOR BATTERIES UP TO 100 Ah RECOMMENDED BATTERY
20. is extremely poor if the generating set is mounted on a light weight flimsy surface such as plywood which will only amplify vibrations If mounting on a thinner surface cannot be avoided this should be at least be reinforced with stiffening struts or ribbing If possible holes should be drilled or cut through the surface to help reduce the resonance Covering the surrounding walls and floors with a heavy coating plus foam will certainly improve the situation 5 Never connect the base of the generating set directly to walls or tanks refer to Figure 1 INSTALLATION Figure 1 Mounting of the Whisper generating set 2 5 VENTILATION 2 5 1 The Genverter General normally draws air from the engine compartment or machine room An engine compartment with natural ventilation must have vent openings of adequate size and location to enable the Genverter to operate without overheating To allow an ample supply of air within the temperature limits of the generating set an opening of at least 100 cm2 is required ma T X wrong V OK 2 6 CONNECTIONS 2 6 1 The Genverter GV4 Piccolo comes supplied with all supply and Overview output lines i e cooling water connections exhaust fuel lines etc already connected to the e
21. ld be considered to compensate for voltage reduction Connect the cables as described in section 4 1 When two batteries are used in series to provide IN a 24 Volt supply system never take off 12 Volt starting power from one of these batteries This will result in severe damage to both batteries within a short time 16 Be sure that all tri installations including all safety systems comply with all required regulations of the local authorities All electrical safety shutdown and circuit breaking systems have to be installed on board as the generating set itself cannot be equipped with such equipment for every possible variation The boats power supply system should be suitable and safe for the AC voltage which is applied and the power that will be generated Special attention has to be paid on dividing the system in branches which are fused individually It is absolutely essential that each and every circuit in the electrical system is properly installed by a qualified electrician 3 5 FUSE An output fuse between the GV4 Piccolo and the electrical installation should be installed to protect the installed electrical system A maximum single phase output current applied is 18 Amps The fuse must be of the slow reacting type For electrical motors connected to the system a motor protection switch must be installed December 2014 M GV4 Piccolo for marine applications EN 3 6 GROUNDING The
22. neutral and not only phases or line and there should be provisions with the aid of timers to prevent relays from clattering Whisper Power recommends the installation of a Systemswitch as the power source selector This works automatically when the generating set is not running the input remains in the land line position and as soon as the generating set is running the Mass Systemswitch switches automatically after 10 seconds delay time over to the generating set position In all situations the transfer switches between land line inverter and Genverter should switch both neutral and L1 EN M GV4 Piccolo for marine applications December 2014 J 17 ELECTRICAL INSTALLATION 12 VOLT 4 4 1 4 KR W N N Ol Figure 21 Connecting the battery cables to the starter motor 9 10 18 INSTALLATION SPECIFICATIONS GENERAL Mount the generating set directly without additional vibration dampers on a solid surface Mount the cooling system for the engine Connect exhaust system Connect fuel supply line to the water separator fuel filter Connect fuel return line to the fuel tank Connect remote panel just plug in Connect the AC cable from the AC box to the power source selector Connect the battery cables to the starter motor as illustrated in Figure 21 Battery cable Connect plus and minus from the 12V starter battery to the battery cables Install a Whisper Po
23. ngine and inverter The supply lines are fed through the capsule s front base The connections are marked as shown in Figure 2 All electrical connections cable types and sizes must comply with the appropriate national regulations Supplied cables are temperatures the electric output will be lower To minimise these effects the engine room temperature must not be more than 152C above the outside ambient air temperature Apply a combination of ventilators blowers and air intake ducting to meet the temperature limit The air inlet ducts should run to the bottom of the engine compartment to clear fumes from the bilge and to circulate fresh air Air outlets should be at the top of the engine compartment to remove the hottest air An engine compartment blower should be used as an extraction ventilator to remove air from the engine room In cases where it is impossible to meet the above mentioned temperature limit by using engine compartment ventilation connections are to be made for an air inlet directly to the Genverter enclosure Air inlets should be louvered where appropriate to protect the engine room and to protect the generating set from water spray emperatures up to 70 C meet higher temperature y through conduits king installation on the system read the section safety instructions December 2014 M GV4 Piccolo for marine applications EN Fuel in Fuel out Sea water in Si
24. olo for marine applications December 2014 following installation materials are required a skin fitting a sea tock a water strainer hoses and clamps In order to at a minimum the sea water intake system i e sea cock thru e suction resistance in the line hull fitting inlet filter etc must have an inner diameter of at least 12 5 mm di as short as possible Raw water plumbing should avoid bends as The suction hose should be kept much as possible Restriction of raw water flow caused by kinked hoses undersized pipes or connections will reduce the engine cooling capability This is the main cause for overheating of an engine When in doubt check the coolant flow rate using a stopwatch and by holding a pail of a known volume under the wet exhaust outlet The flow rate should be 8 to 12 litres min 2 84 Installation of through hull fitting It is good practice for yachts to use a hull inlet fitting with an integrated strainer water scoop For propulsion engines in motorboats the water scoop is often mounted against the sailing direction to induce more water intake for cooling Gs CN 2 O e S gt E 2 LA lt set 2 1 Water level 5 Air vent Siphon breaker 2 Water exhaust separator 6 Water strainer 3 Seacock 7 Seacock 4 Waterlock Figure 6 Raw water cooling system MIN 60CM 24 gU o 3 oO N N e Q gt ANING DIRECTION
25. phon breaker loop out Siphon breaker loop in Figure 2 Connections of the GV 4 Piccolo 2 7 FUEL SUPPLY 2 7 1 Fuel tank Fuel tanks should be made of appropriate material such as stainless steel or plastic Steel tanks should not be galvanised or painted inside Condensation can occur in metal tanks when temperature changes Therefore water accumulates at the bottom of the tank and provisions should be made for the drainage of this water The tank will need a filling connection a return connection and an air ventilation connection which will require protection against water entry EN M GV4 Piccolo for marine applications December 2014 INSTALLATION power output Battery connection Bottom view Some official regulations do not allow connection points at the base of the fuel tank connections are to be made at the top of the tank with internal tubing down to a few cm above the bottom of the tank Using the existing fuel tank of the car engine the fitting should be carried out with extra care Both a supply line and a return line should be installed and go into the tank from the top Interference of the two systems car engine and Genverter engine should be avoided Motor control and 3 phase INSTALLATION 2 7 2 Apart from the machine fuel pump the generating set is Fuel lift pump supplied with a separate fuel lift pump therefore the tank can be installed at a lower level than the generating s
26. r recommends ending the return line on the top of the tank When the return is on the top in case of a leakage the return line cannot overflow because of siphoning One will only need a fuel cock in the fuel supply line When the tank is below the generating set Figure 3 we recommend ending the return line on the bottom of the tank A below the inlet of the supply line In this way the fuel cannot drain back into the tank when the engine is stopped as the return line will not let air in This prevents starting trouble caused by air in the fuel supply line Both supply and return fuel pipe lines should be appropriate material and 8 mm outer diameter tubing The quality of the tubing of fuel pipes could be submitted to local regulations depending on the application of the boat The fuel pipes can be plumbed to the flexible hoses which are on the generating set and have a connection to fit to 8 mm pipe This fuel lines fulfils CE standards and are according to ISO 7840 A2 It is important to avoid bends in the pipes as they could trap air INSTALLATION on a raw water pump heat exchanger and water injected exhaust Keel cooling means cooling the coolant in case of the GV4 Piccolo this is oil by circulating the hot coolant through a space in the keel or through a double walled skin of the boat through a box cooler welded in a steel boat using a big tank or any other external cooler Most of the time using keel cooling one apply
27. re 17 how to mount the rubber in a safe way When any doubt an extra safe guard could be constructed from steel wire or chain Figure 17 Mounting bracket in rubber with safeguard 15 INSTALLATION 3 ELECTRICAL INSTALLATION 12 VOLT 3 1 ENGINE CONTROL SYSTEM Engine control standard 12V is incorporated in the PMG Power Module for Genverter Use the PMG or a separate DDC box to operate the generator 3 2 STARTER BATTERY For starting the GV4 Piccolo requires a 12V starter battery with at least 55 Ah The GV4 Piccolo can be connected with the main engine battery or have its own battery We strongly recommend the use of a separate battery for the GV4 Piccolo and to keep the wiring system for the boat engine and the domestic DC supply system completely separate and individually connected to separate batteries However the negative of all the batteries on the boat should be interconnected to avoid difference in the voltage level of the earth on different places causing trouble to electronic devices which might be in the system The above recommendation is not valid for boats having the starter battery of the boats engine or other auxiliary equipment positive grounded When this is the case an expert should be Disconnect the battery leads if electrical welding is to be carried out otherwise damage will be caused to the diodes of the alternator As explosive hydrogen gases may be discharged during charging the batte
28. ry should be located in a well ventilated room Ensure that the supplied battery cable connectors are properly fitted and never remove during or shortly after charging as sparking can occur which may ignite the hydrogen gasses 3 4 AC POWER SYSTEM 230 VOLT The electric power supplied by the GV4 Piccolo is of a high voltage and dangerous to people Before working installation on the system read the sections on safety in the users manual Generators used on boats that are operated in a hazardous environment have often to fulfil special regulations and additional measures have to be taken accordingly consulted good condition when the generating set is not used A battery charger is not included in the standard supply A high efficiency battery charging unit can be ordered from Whisper Power which is able to charge both the boat s main battery and the starter battery Also a small charger can be used to charge the starter battery only 3 3 OTHER RECOMMENDATIONS AND WARNINGS The battery should be secured for rough sea conditions and the terminals should be insulated For extra safety the battery can be enclosed in a wooden plastic fiberglas etc non metal box Even when the earth return system is applied a negative battery cable should be used and the boat should not to be used as a conductor Battery cables are not included recommended 1 5 m 10mm2 if longer cables are required a larger cross sectional area shou
29. tem 230 Volt masa GA EE EE EE ENEE 16 3 3 RA 16 3 6 SA RRE E o CO 17 3 7 PAKA AA AA AA AAP 17 3 8 Transfer switch AA 17 4 INSTALLATION SPECIFICATIONS AKA KAANAK AKA EEEE eeen AA AA GAGANA AA 18 4 1 A AA AP 18 4 2 Commission AD EEn 18 4 3 Tena AA AN AA AA AA AA 18 4 4 specification OF TNE ACCESSONIES E 19 4 5 Watsnel ge an E E AA AA o GA 19 December 2014 M GV4 Piccolo for marine applications EN CE TABLE OF CONTENTS 5 DIAGRAMS S DRAWINGS eege 23 5 1 lend glare Mel BA ee ee Tennent 23 5 2 PSG E tte H Reen 25 EN M GV4 Piccolo for marine applications December 2014 3 INTRODUCTION 1 INTRODUCTION 1 1 USE OF THIS MANUAL This manual serves as a guideline for the safe and effective installation of the WhisperPower GV4 Piccolo Genverters for marine applications It is obligatory that every person who is involved with the installation of the Genverter must be completely familiar with the contents of this manual and that he she carefully follows the instructions contained herein To ensure reliability and durability of the equipment it is very important that the installation is carried out with the utmost care and attention To avoid problems such as temperature problems noise levels vibration etc the instructions set out in this manual must be followed and all installation work must be carried out only by qualified authorized and trained personnel consistent with the locally applicable standards and t
30. the installation is carried out with the utmost care and attention To avoid problems such as temperature problems noise levels vibration etc the instructions set out in this manual must be followed and all installation work must be carried out professionally 2 2 LOCATION When looking for a proper place for a GV4 Piccolo in a boat all relevant aspects have to be taken into account e Accessibility e Solid foundation e Space to mount the exhaust e Aroute to fit the fuel lines Oo Since the Whisper Genverters have extremely compact dimensions they can be installed in tight locations Please consider that even almost maintenance free machinery must still remain accessible When selecting the location area in which to mount the INSTALLATION 2 4 INSTRUCTIONS FOR OPTIMAL SOUND AND VIBRATION INSULATION Position the GV4 Piccolo as low as possible in the vessel The Genverter is secured to the base frame inside the canopy by means of a double flexible engine mountings system This frame is must be solidly mounted in the vessel not using rubber mountings again When it is possible to mount the unit directly on the vessel s frames this has advantages in preventing vibrations by resonance 2 4 1 Further recommendations Whisper generating sets are standard equipped with a sound cover canopy This sound cover has been designed to give effective sound insulation For optimum sound and vibration dampening the following factors should
31. top of the goose neck to the water lock The water lock must be installed at the lowest point of the exhaust system refer to Figure 6 ref 1 The exhaust hose must have an inner diameter of 40 mm no less no more The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0 8 psi 60 cm water pressure refer to the user s manual and total length up to the outlet or water separator does not exceed 2 5 m The exhaust hose descends from the capsule to the water lock Then the hose rises maximum lift 120 cm via the goose neck to the through hull exhaust outlet situated Minimum 50 mm above the water line refer to Figure 6 ref 5 The goose neck must be vertical and situated preferable along the ship s keel centre line It is recommended to install an extra muffler see Figure 6 ref 2 close to the Figure 8 Wrong siphon breaker hose routing non Whisper Power siphon breaker Check the air vent at regular intervals Open clean and lubricate the valve as required Figure 8 2 9 EXHAUST SYSTEM Inter cooling is almost always combined with a wet exhaust system Water is injected in the exhaust system of the Genverter In this way the cooling water that has passed the heat exchanger is mixed with the exhaust gases Temperature and volume of the gases are thereby reduced considerably so that a rubber exhaust hose can be used and the level of noise is reduced as well However a dry exhaust is
32. wer battery charger optional 4 2 gt COMMISSIONING TABLE Check if the cooling system for the engine is properly installed Check if the exhaust system is properly installed Check maximum length of exhaust hose diameter of exhaust piping Check all coolant connections Check the AC cables and the grounding Check if an AC breaker is installed before or after the power source selector When there is only a circuit breaker use it to disconnect the generating set from the grid Check all DC connections check if the battery switch circuit breaker is closed Open the fuel valve Check if there are no air leaks in the fuel supply line and check if the lift of the fuel is less than 1 meter Check if there is no air in the water fuel separator Check if the air intake in the canopy is not blocked Check the oil level and colour of the oil To bleed the fuel system Push the Start on the local control not on the kn i en SA A N Y a 11 12 13 14 16 17 18 remote panel and hold at least 5 seconds and as long as necessary to t Start the engine by pushing the start button Check when the Genverter 4s running the delay of some econds in the power source selector transfer Check voltage and frequency under no load conditions Check if the Genverter increase speed when loaded more Check if the Genverter can bring the full load Check if the Genverter can sp
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