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Installation manual W-SQ 6 / 8 /12 / 16

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1. a d S Y T N y S E K S Y gt Fd es ETE EE 7 pa IN 5 1 W LI T We SE 7 N Ti FR X A 59 9 m OQ Te 9 aad Ha gt l i GENES Se Tas no E ie Teen SE ON 2 31145 Kh i Aum dund jang ny a E EE 5 208 acc ERA a E GE O 197718 a e glaz lt L lard jen aar eeuse ON d el N Sua A ve 24 fol ve 14 i E n e aS zu E d 73 B DIDS a u E El 2 se E Y RE F y EIE E E ebe 7 a 1 EJ La zw ES EU y 2 Lu GEES y E LE S MV CH As uc Ka Hs ma ES JE EH t SS S E Is a IE 3 ES D md 3 Ra SE mr EES a Z US Wei CES JN aam d Ss T 9 Ly amp rl sd lj Te Eil KS EE TATE Fol a Q u b D e 2 d EEE 7 pu EE gt I1 mm E E ds 110 DT _ ww a is I3 10 gt E H i GT N A a m Tana Lu ween D 2 4s S a S Ch EN BE 1 E 7 pls gt xou 138 K K x E Li T c AN GERS 1 3y 1 Gem SE ful n ED On gt E ES EI ET a ONSE AE ELE EE E je 1 GN ao 3 E i 8 E Deje i gt 2g Y f 4 E lt v D EN ju T A EC Z gm CH a H e nae 1 E e SC E i 1 x D E 1 m E E d l Eg ar S 5 ch 8 Ix EE zo a To i52 gt a TES SE af EL ZEE age lel od Sie E tg Ek i d S
2. Fig 45 Outer dimensions mm W SQ8 CONNECTIONS W SQ8 BOX DIMENSIONS W SQ8 exhaust 1 length fuel hose 5 16 8 mm width radiator alternator 3 4 19 mm height radiator engine 114 32 mm weight battery AWG 2 25 mm2 battery AWG 2 25 mm2 POWERCABLES ISO 13297 annex A not included 3x6 mm2 not included REMOTE CONTROL 15 meter 8 wire communication cable included EN W SQ6 8 12 16 for mobile applications November 2008 900 mm 35 4 575 mm 22 6 640 mm 25 2 335 kg 45 DIAGRAMS amp DRAWINGS N e 4 14 DIMENSIONS W SQ12 LC CD ED aL UC ccm el ie ee ae a GEE power SI Ge EE Fig 46 Outer dimensions mm W SQ12 CONNECTIONS W SQ12 BOX DIMENSIONS W SQ12 exhaust 1 Ve length 1060 mm 41 7 fuel hose 5 16 8 mm width 575 mm 22 6 radiator alternator 3 4 19 mm height 640 mm 25 2 radiator engine 114 32 mm weight 380 kg battery AWG 2 25 mm2 battery AWG 2 25 mm2
3. 62 1 50220042 Insul blanket 35x60 exhaust hose 1 1 2 63 1 50230523 Absorbtion muffler steel 11 2 64 1 50230524 Ressonance muffler steel 11 2 65 1 50230525 Insul blanket 80x75 muffler SDHC 1 1 2 66 2 50221403 Pipe nipple 11 2 x300mm galvanised 67 2 50221423 Parallel male coupling 11 2 galvanised 68 2 50221413 Straigt coupling f f 11 2 galvanised 69 3 50221663 U clamp 48 mm M10 70 3 50221664 Bracket U clamp 25cm M10 48mm passivated 71 6 50211406 Washer SP M10 72 6 50211447 Washer spring SP M10 73 6 50211466 Nut hexogonal SP M10 75 1 50221473 Elbow 90 degr m f gavalvanised 11 2 TOTAL 40201875 DRY EXHAUST KIT 11 for W SQ6 8 12 and 16 RADIATOR COOLING KIT ALTERNATOR 230VAC for W SQ6 8 and 12 no att article no description 31 1 50230304 Radiator cooler AP 300 2 E 230VAC 32 2 50221103 Straight reducer m f 1 3 4 33 1 50221063 Male nipple 3 4 34 1 50221043 TEE fittings 3 4 35 3 50221004 Male hose connection 3 4x20 38 1 50212405 Temperature switch 35 45 degr 39 4 50201121 Vibration mounting 30x25 40 4 50211152 Bolt hexagonal ZP M8x16 41 8 50211465 Nut hexogonal SP M8 42 8 50211405 Washer SP M8 43 8 50211445 Washer spring SP M8 44 8 50220011 Hose vacum SAE100R4 3 4 19x31 5mm 45 6 50221502 Hose clamp stainless19 29 46 8 50221599 Hose support 35x15 mm galvanised 47 1 50230529 Bracket expansion tank for 50230531 47 1 50230531 Expansion tank 20 mm 47 1 5023
4. Model Maximum single phase output current W SQ6 25 Amps W SQ8 35 Amps W SQ12 52 Amps W SQ16 70 Amps EN W SQ6 8 12 16 for mobile applications November 2008 The fuses must be of the slow reacting type For electrical motors connected to the system a motor protection switch must be installed 2 GROUNDING The AC alternator windings are not grounded The housing of the alternator and all other metal parts are grounded To make a connection between neutral and ground is necessary as part of a specific insulation failure protection System It is possible that the electric installation in the vehicle must be protected against insulation failures Methods of protection are subjected to rules that can be different depending on the use of the vehicle and local standards Experts in this field should be consulted 3 CABLE For the power cable we recommend the use of 3 wire single 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 4 TRANSFER SWITCH A power source selector switch much be installed between the generating set 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 shore grid power Systems separate Transfer switches to switch o
5. POWERCABLES ISO 13297 annex A e 3x10 mm2 not included REMOTE CONTROL 15 meter 8 wire communication cable included 46 November 2008 W SQ6 8 12 16 for mobile applications EN D whisper Power y DIAGRAMS amp DRAWINGS 4 15 DIMENSIONS W SQ16 Q A gt HDLE 13 X 30 HOLE 13 X 20 i 5 i L i C iL EI Ci HHDH KEREN III BEREN LLL I LLL UI Fig 47 Outer dimensions mm W SQ16 CONNECTIONS W SQ16 BOX DIMENSIONS W SQ16 exhaust 1 Vo length 1160 mm 45 7 fuel hose 5 16 8 mm width 680 mm 26 8 radiator alternator 3 4 19 mm height 700 mm 27 6 radiator engine 1 32 mm weight 454 kg battery 35 mm2 battery 35 mm2 A template to drill the mounting holes of the W SQ16 is POWERCABLES ISO 13297 annex A included in the delivery e 3x16 mm2 not included REMOTE CONTROL 15 meter 8 wire communication cable included EN W SQ6 8 12 16 for mobile applications November 2008 47 D whisper ION Y Kelvinlaan 82 9207 JB Drachten Nede
6. alternator including regulator 50 Amps 50 Amps Note that this value must be reduced by the power to drive the cooling fans of the radiators EN W SQ6 8 12 16 for mobile applications November 2008 25 6 whisper INSTALLATION SPECIFICATIONS 5 Ro 34 INSTALLATION MATERIALS BATTERY INSTALLATION KIT 70 Ah for W SQ6 8 and 12 no aty article no description dimensions 51 1 42000700 Whisper Power AGM Battery 12V 70Ah 70Ah 52 1 43011000 battery charger IVO SMART 12 10 53 1 48060100 battery terminal M8 54 1 48060200 battery terminal M8 55 1 48456902 isolation cap 56 1 48456914 isolation cap 57 1 49009005 battery switch 250 Amp 58 4 4503002508 cable connectors M8x25 TOTAL 40230210 BATTERY INSTALLATION KIT 70 Ah BATTERY INSTALLATION KIT 160 Ah for W SQ16 no aty article no description dimensions 51 1 42001600 Whisper Power AGM Battery 12V 160Ah 160Ah 52 1 43011000 battery charger IVO SMART 12 10 53 1 48060100 battery terminal M8 54 1 48060200 battery terminal M8 55 1 48456902 isolation cap 56 1 48456914 isolation cap 57 1 49009005 battery switch 250 Amp 58 4 4503003508 cable connectors M8x35 TOTAL 40230220 BATTERY INSTALLATION KIT 160 Ah FUEL KIT no aty article no description dimensions 41 2 50221203 Straight coupling 8 mm 42 1 50230090 Fuel strainer water separator M14x1 5 mm 43 2 50221618 Parallel male stud coup
7. 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 The resonance muffler should be fitted according to direction of the gas flow indicated In the kit are clamps to mount the exhaust pipes to stainless steel bars These bars should be mounted to the chassis of the vehicle 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 figure 19 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 27 Mounting bracket in rubber with safe guard 19 INSTALLATION whisper Power 2 5 4 Electrical installation 12 Volt 1 DIGITAL DIESEL CONTROL SYSTEM The electrical control system is standard in 12 Volt with negative earth Non earth return is available as an option All electrical wiring has been prepared on the generating set to the control panel prior to despatch from the factory The engine is controlled by a very advanced microprocessor based system Digital Diesel Control The black box containing the microprocessor is located on top of the alternator A local control panel is on the generating set Remote control A remote control panel also containing a micropr
8. 12V Max lift fuel pump im im Cooling Radiator cooling Radiator cooling Cooling pump Whisper Power self priming raw water impeller pump PTO driven Model cooling pump M M12 Minimum water supply Alternator 9 15 l min 18 22 l min synchronous brushless maintenance free water cooled Voltage regulation capacitor optional AVR Output power at 50Hz power factor cos phi 1 5 7 kW 8 KW Battery charger alternator including regulator 40 Amps 50 Amps Note that this value must be reduced by the power to drive the cooling fans of the radiators W SQ12 AND W SQ16 Model W SQ12 W SQ16 Dimensions I x w x h 106 x 58 x 63 cm 116 x 58 x 70 cm Weight including sound shield 380 kg 440kg Max operation angle 25 25 Remote panel 15 m cable Digital Diesel Control System Battery capacity min 12V 70Ah 12V 120Ah Fuel consumption 1 5 4 I hr load dependent Model fuel pump Electrical driven 12V Mechanical driven manual priming Max lift fuel pump im im Cooling Radiator cooling Radiator cooling Cooling pump Whisper Power self priming raw water impeller pump PTO driven Model cooling pump M12 M16 Minimum water supply 18 22 l min 20 25 l min Alternator synchronous brushless maintenance free water cooled Voltage regulation capacitor optional AVR Output power at 50Hz power factor cos phi 1 12 kW 16 kW Battery charger
9. PA NINAS3A INIH 2d m m BS 5 le 318v Dvd 318v 2 5 S 38 la TANYA 1DALNOO E 5 mE m ate W 310432 OL a DUO OU LH Ley EN zu 2 2 Z 3 E Os S d C qup Ms gr a 1 8 Ka E 5g X Si Ee y R BE l ZC I3 L LY ER 9Jnjej N JJeJs M 2 g g d US 2 044405 855g 041610 N EK d d3NVd TUS LD 19901 ee ME 1 94 CEE NADSE n HDIves3N32 DL Fig 37 Layout generator control for W SQ16 with 230VAC radiator fan November 2008 W SQ6 8 12 16 for mobile applications EN 36 amp whisper Ier es DIAGRAMS amp DRAWINGS 4 5 WIRING COLOURS W SO6 8 AND 12 Cable code number colour cross section battery gt starter motor red 25 mm2 starter motor gt DDC 1 red 6 mm2 starter motor gt LCP 13 red 2 5 mm2 battery gt ground black 25 mm2 ground gt LCP ground GND 2 black 4 mm2 DDC gt glow plugs 3 brown 4 mm2 DDC gt starter solenoid 4 yellow 2 5 mm2 LCP gt fuel lift pump 5 brown 1 5 mm2 LCP gt fuel lift pump 15 black 1 5 mm2 DDC gt LCD 5 grey 1 5 mm2 DDC gt oil pressure switch 6 purple 1 mm2 LCP gt oil pressure switch 6 purple black 1 mm2 DDC gt water temperature switch 7 blue 1 mm2 LCP gt water temperature switch 7 blue black 1 mm2 DDC gt exhaust temperature switch 8 blue green 1 mm2 LCP gt exhaust temperature switch 8 blue rose 1 mm2 DDC gt fuel solenoid hold 9 green 1 5 mm2 DDC gt fuel solenoid pull 20 pin
10. W SQ8 230V 1500rpm Mobile ungrounded 41107020 W SQ12 230V 1500rpm Mobile 41107026 W SQ12 230V 1500rpm Mobile ungrounded 41108020 W SQ16 230V 1500rpm Mobile 41108026 W SQ16 230V 1500rpm Mobile ungrounded For other models see our website www whisperpower eu WARNING A 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 manual EN W SQ6 8 12 16 for mobile applications November 2008 1 2 GENERATING SETS FOR VEHICLES 1 2 1 Marine and mobile generators Whisper Generators originate from the marine sector But there are also specially designed Whispers available for mobile applications suitable for supplying power on board of vehicles to use professional apparatus and equipment strong lightning and air conditioning etc The cooling system and exhaust system on vehicles is completely different from standard marine systems On vehicles the engine and alternator are individually cooled by radiator with an electric 1
11. ba P jog i sl T Ke Y a um ERN ITLAATKIT IN gt EXHAUST E 8 g 1 8 mE HH lt D TE EEE EEE EE Le N i y K SE UL IE Ze Oc EE WM gt N EER um IN iE KOELWATERKIT GENERATOR RADIATEURKOELING G ADIATOR COOLER KIT ALTERNAT E ET p lt E N d Ki K Figure 33 radiator cooling kit engine exhaust kit and radiator cooling kit alternator EN W SQ6 8 12 16 for mobile applications November 2008 4 whisper INSTALLATION SPECIFICATIONS gt ii id RADIATOR COOLING KIT ALTERNATOR 230VAC W SQ16 no att article no description 31 1 50230307 Radiator AP 430 230VAC 32 1 50221103 Straight reducer m f 1 3 4 33 1 50221064 Male nipple 1 34 1 50221044 TEE fitting 1 35 2 50221010 Male hose connection 1x25 35 1 50221004 Male hose connection 3 4x20 38 1 50212405 Temperature switch 35 45 degr 39 4 50201121 Vibration mounting 30x25 40 4 50211152 Bolt hexagonal ZP M8x16 41 4 50211465 Nut hexogonal SP M8 42 4 50211405 Washer SP M8 43 8 50211445 Washer spring SP M8 44 6 50220012 Cooling water hose smooth 1 25x34 mm 44 1 5 50220011 Cooling water hose smooth 3 4 18x27 mm 45 2 50221502 Hose clamp stainless19 29 45 4 50221503 Hose clamp stainless 26 38 47 8 50221599 Hose support stainless 35x12 mm 47 1 50230529 Bracket expansion tank for 50230531 47 1 50230532 Cap
12. be clear that it is not possible to combine the cooling of the engine and alternator in one radiator system Furthermore it will be clear that it is very difficult to cool an alternator optimally with the aid of a radiator in conditions with high ambient temperatures 1 23 Why the alternator should be cooled by water For normal industrial use alternators are cooled by air This requires a flow of air through the alternator of many m3 per minute With the air the noise comes out into the open Generators on vehicles can only made silent by full enclosure in a sound shield canopy The only opening in the Whisper canopy is the inlet for combustion air For that reason the alternator is cooled by water Although cooling the alternator by circulating water through a radiator is not ideal it is much better than by air Therefore aircooled alternators are rarely used in vehicles November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper ower INSTALLATION Y 2 INSTALLATION Figure 4 Schematic installation diagram 2 1 GENERAL 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 noi
13. bottom hanging down Use sealant or kit between the flange and the surface ATTENTION In any case it is necessary to open a hole for air inlet EN W SQ6 8 12 16 for mobile applications November 2008 2 5 CONNECTIONS The generating set comes with all supply lines and output cables i e electric cables coolant connections exhaust fuel lines etc already connected to the engine and generator The supply lines are fed through the capsule s front base The connections are marked as shown in figures 7 till 10 All electrical connections cable types and sizes must comply with the appropriate national regulations Supplied cables are rated for ambient temperatures up to 70 C If the cables are required to meet higher temperature requirements they must be run through conduits ATTENTION Before working installation on the system read the section safety instructions INSTALLATION 4 whisver Power Fig 7 Connections W SQ6 for mobile application 01 02 03 04 05 06 07 08 10 11 12 13 Y Coolant generator in Battery positive Fuel out 8mm Fuel in Z8mm Battery neg
14. of the engine However when the radiator is above the engine one can only fill the system to the level of the manifold Additional filling has to be done via the expansion tank For large engine cooling systems with long pipes or for extra reserve there is an extra large expansion tank with a content of 7 litres and an alarm for low coolant level that can be supplied as an option refer to figure 16 Figure 17 7 litres optional expansion tank with low level alarm 15 INSTALLATION whisver Power When mounting the radiators it is important to take care that the outgoing connection which is the connection to the engine inlet is on the top position refer to figure 18 detail A and is connected to the expansion tank Also when the radiator is mounted flat at the bottom of the vehicle the outgoing connection is connected to the expansion tank This is the best way to have the system release air and to add liquid when necessary The expansion tank must be fitted in the outlet of the radiator the inlet pipe of the engine side mount FS 7 bottom mount A Ga E 1 SC Figure 18 Outgoing connection connected to the expansion tank When both radiators are flat mounted on the roof the expansion tanks should be mounted a little higher refer to figu
15. output power of the generating set Y 4 OTHER RECOMMENDATIONS AND WARNINGS The battery should be secured for poor road 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 vehicle should not to be used as a conductor The battery cables are supplied in a standard length of 1 5 m if longer cables are required a larger cross sectional area should be considered to compensate for voltage reduction When two batteries are used in series to provide 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 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 A discharged during charging the battery 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 22 November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper Power INSTALLATION Y 2 5 5 AC power system 230 Volt The electric power supplied by the generator is of a
16. 0532 Cap tank 0502 30531 TOTAL 40201878 RADIATOR COOLING KIT ALTERNATOR 230VAC for W SQ6 8 and 12 RADIATOR COOLING KIT ALTERNATOR 12VDC FOR W SQ6 Same as article no 40201878 except no att article no description 31 1 50230302 Radiator cooler AP 300 2 E 12VDC TOTAL 40201872 Radiator cooling kit alternator 12VDC for W SQ6 RADIATOR COOLING KIT ALTERNATOR 24VDC FOR W SQ6 Same as article no 50201878 except no att article no description 31 1 50230303 Radiator cooler AP 300 2 E 24VDC TOTAL 40201868 Radiator cooling kit alternator 24VDC for W SQ6 28 November 2008 W SQ6 8 12 16 for mobile applications EN EDUC INSTALLATION SPECIFICATIONS DeTINAL E E Ir Ha a y M sa d dm mc m l i 7 RADIATOR DAK MONTAGE S RADIATOR ROOF MOUNTEL KOELWATERKIT MOTO ADIATEURKOELI ie ADIAT OOLER KIT ENGINE amp E U W x 8 2 Salt Du gt D fe
17. 2 5 mm2 B terminal alternator gt starter motor 21 red 6 mm2 DDC gt R terminal alternator 18 wit 1 5 mm2 DDC gt L terminal alternator 19 orange 1 5 mm2 DDC gt current measuring transformer 11 black 1 mm2 DDC gt current measuring transformer 11 red 1 mm2 DDC gt LCP 12 black 1 5 mm2 DDC gt LCP 14 red 1 5 mm2 DDC gt LCP 16 red green 1 5 mm2 DDC gt generator AC output 33 brown 1 mm2 DDC gt generator AC output 33 blue 1 mm2 DDC Digital Diesel Control Unit LCP Local Control Panel 38 November 2008 W SQ6 8 12 16 for mobile applications EN whisper Power 24 DIAGRAMS amp DRAWINGS 4 7 AC WIRING DIAGRAM 230V 50HZ EARTH AND NEUTRAL NHT CHNNECTED STATOR GREEN 1 EXCITATION WINDING GREEN 2 CURRENT TRANSFORMER RED 3 230V 50Hz MAIN WINDING BROWN L1 CAPACITOR MAIN WINDING EARTH AND NEUTRAL CONNECTED CURRENT TRANSFORMER 230V 50Hz DCC ct 1 BROWN L1 CAPACITOR Fig 38 AC wiring diagram EN W SQ6 8 12 16 for mobile applications November 2008 39 rg E DIAGRAMS amp DRAWINGS Power gf 48 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 230VAC MAIN CIRCUIT BREAKER GENERATOR L AC LOAD SS en CIRCUIT l BREAKER l End AIR FANS 6A Fig 39 Electrical diagram for standard fan control using 230V AC radiator fans PUMP BAT GENERATOR PS ES 230VAC L1 FUSE 5A 11 FUSE 6 3A 14
18. 2V 24V or 230V driven fan The radiators can be fitted below on top or in the side of the vehicle The exhaust is of the dry type and includes a stainless flexible bellow and high quality mufflers Never use rubber exhaust hose nor plastic A exhaust parts in a dry exhaust system as applied on vehicles Unless indicated otherwise Ee SR 5 Figure 1 Typical vehicle application radiator side mounted INTRODUCTION whisper Power Figure 2 Typical vehicle application radiator top mounted G S e Figure 3 Typical vehicle application radiator bottom mounted Y 1 2 2 Why two radiators The optimum engine operating temperature is between 87 and 92 Celsius The radiator reduces the temperature of the cooling liquid by only 5 C to 12 C The returning cold coolant therefore has a minimum temperature of approx 75 Celsius The alternator should be kept as cool as possible In practice an alternator starts getting less efficient above 40 Celsius It is hardly possible to cool down the coolant of the alternator below 40 by using a radiator When a vehicle is in the sun on a parking place the ambient temperature itself could be 40 Celsius Because of the divergence in the working temperature of engine and alternator it will
19. 4 1 LAYOUT GENERATOR CONTROL FOR W SQ6 8 AND 12 WITH 230VAC FAN P N ay N LI cc E d r Nc uum 7 e o Xx D Ge D S gt 4p S T T D N E Ua d o S z KE c Ee NG BS QO de 9 038 d TT 9 039 ER 5 lies ET ie az A e SEM 31H T zei E ps Jund ar v3 x YOT d tid C I zx S oF E zm da ECNE 1 SIE Ss M Ce m 2 M 123 lard ons zu AOTRUU d x LA y ve 24 s we U a E d E OP amp d jel 4g 2 at EI aq S BEZE a E Om a Fi ala E ide REE K EL x amp N3300 038 e n je x ELE In 133 Em E EE TE Jef En 3 5 aa E pe p c Ue SS Bl Be O amp Jj y UJ S E l moa 1 Lo ya E 4s z a Pi 8 84 E E und Q io z Un HE Eu ER 5 NS x 1 ES Io 3 a d jeLuE OND N ns X Teal SS NEEN E a Geff a e 31 E 1 T3 ia pu o SS mm bed 10 ci l T Ti
20. 5 6 11 l 15 16 l FUSE 5A FUSE 5A 80 70 45 350 230VAC 230VAC TRANSFORMER 230V 115VAC 200VA 41 GENERATOR K1 23OVAC N 4 44 THERMOSTAT COOLER 12 RADIATOR COOLER RADIATOR COOLER ENGINE GENERATOR FUSE 6 3A ENGINE GENERATOR TERMINAL BLOCK 12VDC 230VAC JUNCTION BOX AIR FANS TRAFO 230 115VAC 230VAC 230VAC 230VAC S E 9 z E DIMENTION BOX 270x270x180 MM E o Z 5 D S ke e 2 2 e E a E E e 8 Ss Fig 40 Electrical diagram fan control using 230V GE amp oO of Su SE AC radiator fans with two speeds fans optional Ba B 2 E 2 ES E BSS E E E S 55 a2 or 5 E E So Ze ES 40 November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper Power e DIAGRAMS amp DRAWINGS 4 9 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 12 24 VDC CONTROL PANEL BAT PUMP 2 BAT THERMOSTAT COOLER RADIATOR COOLER ENGINE GENERATOR ENGINE GENERATOR JUCTION BOX AIR FANS TERMINAL BLOCK r O O O 1 2 3 4 5 6 7 8 9 10 Jo 123 4 s e 7 e o t K3 K1 K2 ANI O FUSE O 20 40A IR CU0 75 E T CU0 75 a CU25 O SISISISIS OO OOO O H olololojolo 2 0 olojol HEG 12345678910 45 350 ND 2 5 e E 5 wi E o H 0 m DIMENIONS BOX 160x160x90 MM 6 Z J a a 2 SES Y e 3 tp He Te E gS 9 9pu 22 LU t tc Fig 41 Electrical d
21. 8 31 4 whisper INSTALLATION SPECIFICATIONS gt a RADIATOR COOLER KIT ENGINE 230VAC W SQ12 and W SQ16 no att article no description 1 1 50230311 Radiator AP 430 2 230 VAC W SQ12 and 16 2 2 50221502 Hose clamp stainless19 29 3 1 50221064 Male nipple 1 4 1 50221044 T stuk 1 5 2 50221014 Male hose connection 1x35 6 1 50221103 Straight reducer m f 1 3 4 7 1 50221004 Male hose connection 3 4x20 8 1 50212409 Temperature switch 87 82 degr 9 4 50201121 Vibration mounting 30x25 10 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexogonal SP M8 12 4 50211405 Washer SP M8 12 4 50211437 Washer mudguard SP 8x30x1 5 13 8 50211445 Washer spring SP M8 14 6 50220013 Hose vacum SAE100R4 11 4 31 8x45mm 15 4 50221504 Hose clamp stainless 38 50 16 8 50221597 Hose support SP 45x25 mm galvanised 17 1 50230529 Bracket expansion tank for 50230531 17 1 50230531 Expansion tank 20 mm 17 1 50230532 Cap tank 0502 30531 18 15 50220011 Hose vacum SAE100R4 3 4 19x31 5mm 21 1 50221532 Hose clamp stainless mini 9 11 Optional TOTAL 40201877 Radiator cooler kit engine 230VAC W SQ12 and 16 OPTIONAL INSTALLATION MATERIALS no aty article no description 22 1 50230535 Expansion tank 7L low level alarm switch 32 November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper Power Y DIAGRAMS amp DRAWINGS 4 DIAGRAMS 8 DRAWINGS
22. CK l i E SENSE BAT 2 E WARNING RELAY SE MAX 150 mA Fig 29 Remote box terminals Acoustic alarm or warning lamp One can connect an external max 150 mA relay to generate an acoustic warning or applying a warning lamp etc Be aware of polarity as some relays has a diode inside and should be connected plus to plus en minus to minus as indicated Refer to fig 29 Connection for emergency stop fire alarm switch To connect an emergency stop button or to stop the generator automatically in case of a fire alarm you can use the bypass connection between fastons J7 and J18 on the backside of the local control panel See fig 30 To do so remove this bypass connection and then replace it by 20 November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper Ier INSTALLATION Y an emergency switch or a potential free fire alarm switch with normally closed contacts _ Remove bypass between J7 J18 local control panel rear view Normal operation L Alarm emergency Fig 30 Connection for emergency stop fire alarm switch Automatic starting and stopping Whisper Power cannot be held responsible for damage caused by the unattended running generator using the auto start stop mode or interval mode generator can start unexpectedly When working on the electrical system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from t
23. EN ad ol KEN Ur ie i ze 17 Oe dE d SE Optional control for two speeds fans a See chapter 4 9 S 6 le Fig 36 Layout generator control for W SQ6 with 24VDC radiator fan EN W SQ6 8 12 16 for mobile applications November 2008 35 IS Per Power aw DIAGRAMS amp DRAWINGS LAYOUT GENERATOR CONTROL FOR W SQ16 WITH 230VAC FAN 4 4 Sieg SNN aIDN3 IDs HOLIMS n AS L ONE REN A31 N LVS3N3 s311v8 ASALLvd TET sane HOLINS HOLIAS CWNDILeU TS NOL T qv3H3se ADT VT SS3He IO ANAL Male p S D E SE Ova A 8 y 1Jordeyo aas SUNG ST Sue speeds OM 104 0JJU09 jeuondo sf 2 1 17150H83HL dul daly 33 i G i 5 Si 3 El 1 1 r YIN i i V 7 E iE 1 1 B std poc oc lt o E ES i i X ES i 7 1 i N NTA i M 1 1 ln IE 1 i 3 m D 1 1 EE z 1 Nei Aly XDINDILONPf i OLOW x i TWNOIdO EIER 1 i O i i 1 S N E EEEE eebe t 1 EE SAND ASNH L
24. G D Fig 44 Outer dimensions mm W SQ6 CONNECTIONS W SQ6 exhaust 1 Ve fuel hose 5 16 8 mm radiator alternator 3 4 19 mm radiator engine 1 25 4 mm battery battery AWG 2 25 mm2 AWG 2 25 mm2 POWERCABLES ISO 13297 annex A e 3 x AWG 12 4 mm2 not included REMOTE CONTROL 15 meter 45 ft 8 wire communication cable included BOX DIMENSIONS W SQ6 length width height weight 80 5 cm 81 7 52 5 cm 20 7 58 0 cm 22 8 240 kg 530 Lbs 44 November 2008 W SQ6 8 12 16 for mobile applications EN whisver Power DIAGRAMS amp DRAWINGS Y 4 13 DIMENSIONS W SQ8 ED III III HS LILII gt
25. Lvc00c0v JUV whisper Power NI INSTALLATION MANUAL FOR MOBILE APPLICATIONS W SQ6 8 12 16 1500 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 November 2008 4 whisper TABLE OF CONTENTS 2 CRESTE TABLE OF CONTENTS 1 INTRODUCTION ias 3 1 1 ET EE 3 1 2 Generating sets for Vehicles inc Lote e eoe ot rta 3 1 2 1 Marine and mobile generators ses ssee cesses esse ek AG ek Ke Re Ee Ge Re KO ek ke ee ee nett nennen nnne nnn nnne 3 1 2 2 Why two radilators 5 npe eene aene En ede eeu 4 1 2 3 Why the alternator should be cooled by water 4 2 INSTALLATION dee 5 2 1 General ee ER EE EE a iaeia 5 2 2 ele le ERROR EE EE AE EE RE PEE EA 5 2 3 Instructions for optimal sound and vibration insulation 0 eee ee ee Re Re ee Re emen 6 2 3 1 allge ell les EE aan ae 6 2 4 A ese etii Mun EI 6 2 4 1 ENEE EH 6 2 4 2 Air strainer element 5 2 e OE N RE eI Une dne 7 2 5 STs lee MR o o he EE RR 7 2 5 1 LTR Tee UT 12 2 5 2 Radiator Cooling ice aa 14 2 5 3 Drysexhaust T L ereen b torte etti ia 18 2 5 4 Electrical installation 12 Volt sees ee eee eee eee 20 2 5 5 AC Power System 230 Volt EE 23 3 INSTALLATION SPECIFICATIONS 00d nadan Drap cune 24 3 1 Ci az 24 3 2 COMMISSION table copiada di aos 24 3 3 FTechnicaldata A eate 25 3 4 Installation ma
26. PARE unca 3 Check if the cooling system for the alternator is 2 l f d i 17 Check if the battery charger of the generating set is properly installed Note that air traps must be avoided working max 145 Voli 4 Check if the exhaust system is properly installed 9 NA S l f 18 Close the sound shield and check the noise level Check maximum length of exhaust hose diameter of exhaust piping 19 Stop the generating set and check the engine again for leak f oil fuel lant 5 Check all coolant connections orleakages LON tuekor coolant S OK MO CaS SS aid the grounding Installation checklist available on our website 7 Check if an AC breaker is installed before or after the m i See www whisperpower eu power source selector When there is only a circuit E l Commissioning form available on our website breaker use it to disconnect the generating set from the grid www whisperpower eu 24 November 2008 W SQ6 8 12 16 for mobile applications EN whisper Power xI 3 3 TECHNICAL DATA W SQ6 EN W SQ8 INSTALLATION SPECIFICATIONS Model W SQ6 W SQ8 Dimensions x w x h 80 5 x 52 5 x 58 0 cm 90 x 58 x 63 cm Weight including sound shield 240kg 335 kg Max operation angle 25 25 Remote panel 15 m cable Digital Diesel Control System 12V 60Ah 12V 70Ah Battery capacity min Fuel consumption 1 5 4 I hr load dependent Model fuel pump Electrical driven 12V Electrical driven
27. R OPTIMAL SOUND AND VIBRATION INSULATION Position the generating set as low as possible in the vehicle The generating set is secured to the base frame by means of flexible engine mountings This frame is mounted in the vehicle with additional vibration dampers When it is possible to mount the unit directly on the chassis of the vehicle this has advantages in preventing vibrations by resonance 2 3 1 Further recommendations Whisper generating sets are standard equipped with a sound cover This sound cover has been designed to give effective sound insulation For optimum sound and vibration dampening the following factors should be considered 1 Most important is the structure on which the generator is placed to be stiff Directly below the rubber mountings the structure should be supported vertically to the chassis of the vehicle 2 In larger vehicles a separate and insulated space for the generator will help to damp the noise even further 3 Avoid mounting the generating set in close proximity to thin walls or floors that may cause resonance 4 Sound dampening 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 surroundin
28. TYNOIL O AN31IVH BEIER e 4 TWNOILd DD CYNDI 2303 El D1VNa33171V NL Ti A estia a 6 p Jajdeyo ees S po EE En sue speeds omy 10 ou09 euondo l 29 E vISONAJHL C NT iui i J Za E 1 le al 1 Ve gt LY i TE T ad ole H ess la ut gt phun TA oc 1 En K y i 2 NT 1417 1303 i X mm E E 010 E n m 4 ME DD MALEIS t t 1 E 1 i l 74 II ZD SSXH a E TL eee i a Ge Ea INYOASNVEL N lt o La 3 a INS Be BB z 5 sl Sl SP TI8v5 is C gt E amp 3 B 2 TANYA TDS1NO S RE m a 8 j 310438 OL 2 TESTS S J EES MEN OLS lel _ lt i L _t Bl l IE EXE Eg ao AA AA y a 2 es R ux i go 5 E TONAH 3 DI KO I Tues ERU SER OE jan 4 84 E 70 0 z 044095 25219 041610 E EE Z Z INV eL II Fig 35 Layout generator control for W SQ6 with 12VDC radiator fan November 2008 W SQ6 8 12 16 for mobile applications EN 34 whisver Power es DIAGRAMS amp DRAWINGS 4 3 LAYOUT GENERATOR CONTROL FOR W SQ6 WITH 24VDC FAN
29. adiators on the roof is often the best option from the point of view of keeping the noise of the fans away from people and it will give the best result in dissipating the heat However often this option conflicts with the possible need to keep the vehicle as low as possible Another disadvantage is that the piping has to go through the roof which requires provisions to be waterproof Also negative is that roof mounted radiators are more sensitive for air traps see figure 14 When having enough space it would be ideal to have the radiators vertically mounted on the roof Note that the expansion tank should be above the radiator When having the radiators horizontally mounted on the roof refer to figure 24 enough space 50 mm should be between the roof and the radiator fan to have a free flow of air When the radiators are roof mounted there should be protection against weather conditions To avoid damage while the vehicle is driving at high speed the use of a spoiler could be necessary horizontal vertical Figure 24 Two examples of top mount radiators 3 TWO SPEEDS FAN OPTIONAL To keep the noise as low as possible the fans of the radiators can run at two different speeds As option a control box is available which can be used to drive the fans with two speeds depending on the load of the generator When using 12 24V DC to drive the fans see chapter 4 9 in normal mode the electric motors of the fans are connected in series an
30. al 2 5 2 Radiator cooling 1 GENERAL INSTRUCTIONS The radiators can be mounted below the floor in the side or on the roof of the vehicle Wherever the radiators are mounted the well functioning of the system depends on the well circulation of the coolant Roof mounted radiators bring the most risk for circulation problems because air trapped in the radiators or a low level of the coolant will immediately affect the cooling capacity of the radiators It is recommended to keep the radiators as close as possible to the unit The piping should be fitted as direct as possible When the radiators are above the engine the piping should be fitted below the top of the radiators refer to figure 14 Bents in the piping that can trap air bubbles should be avoided or ventilated refer to figure 15 Piping should not be fitted above the radiator T E OK Figure 14 Air traps should be avoided 14 November 2008 W SQ6 8 12 16 for mobile applications EN INSTALLATION Figure 15 Ventilating an air trap Special attention should be paid to the ventilation of the systems Each installation system is standard supplied with an expansion tank for the coolant which is also used to release air bubbles and makes it possible to add coolant into the system in an easy way This expansion tank should be at the highest point of the system and mounted as high as possible Most cooling problems originate from air traps blocking the ci
31. and dirt and operates as a spoiler The distance between the radiator and the shield should be at least 50 mm Sometimes it is possible to build the radiators and shield on a sub frame that is mounted below the vehicle as a module Measures have to be taken to prevent the hot air circulating and reducing the capacity of the radiators Refer to figure 21 Figure 21 Bottom mounted radiators with shield EN W SQ6 8 12 16 for mobile applications November 2008 Figure 22 Making use of the space below the floor to get an optimal flow of air through the radiators Side mounted radiators Most effective and easy is to mount the radiator in the side of the vehicle if possible below the level of the top of the engine A louvered grid should protect the radiator from rain and objects but must not block the airflow The fan should be inwards which causes the air to blow outwards A disadvantage of having the radiator in the side is possibly more noise of the electric fan and a flow of air that could be felt by people passing by A free flow of air should be guaranteed The ventilation connection of the cooling system that goes to the expansion tank should be in the outgoing coolant flow on top of the radiator air flow l Figure 23 Side mounted radiator side mounted 17 INSTALLATION whisver Power Roof mounted radiators The r
32. ative Coolant engine out Coolant engine in Coolant generator out Expansion tank Exhaust 11 AC power output Remote control November 2008 W SQ6 8 12 16 for mobile applications EN INSTALLATION Fig 8b Connections W SQ8 EN W SQ6 8 12 16 for mobile applications November 2008 01 02 03 04 05 06 07 08 09 10 11 12 Expansion tank 8mm Exhaust 1 2 Remote control AC power output Coolant engine out Coolant generator out Battery negative 25mm2 Fuel out 8mm Fuel in Z8mm Battery positive 25mm2 Coolant generator in Coolant engine in INSTALLATION 4 whisper Power Fig 9a Connections W SQ12 Fig 9b Connections W SQ12 01 02 03 04 05 06 07 08 09 10 11 12 Y Expansion tank 8mm Exhaust 1 2 Remote control AC power output Coolant engine out Coolant generator out Fuel out 8mm Fuel in 8mm Battery negative 25mm2 Battery positive 25
33. 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 generator enclosure With these connections the generating set can be directly connected to an air duct Air inlets should be louvered where appropriate to protect the engine room and to protect the generating set from rain and water spray X wrong V OK November 2008 W SQ6 8 12 16 for mobile applications EN INSTALLATION 50230003 AIRCLEANER 50230005 ADAPTER L 50230006 AIRCLEANER ADAPTER Figure 6 Mounting of the air strainer element 2 4 2 Air strainer element Applying a generator in a vehicle where combustion air is taken in from below the vehicle there is often much dust sand and dirt in the air For these applications Whisper Power prescribes the installation of an air strainer element This air strainer element is in the standard supply but not yet mounted as often the best place to mount it will be different in any installation To install the air strainer element one has to find the best place somewhere on the canopy Figure 6 shows the recommended place but the filter can be mounted everywhere even on the
34. cooler AP 300 2 E 12VDC TOTAL 40201871 Radiator cooling kit engine 12VDC W SQ6 RADIATOR COOLING KIT ENGINE 12VDC FOR W SQ6 Same as article no 40201879 except no att article no description 31 1 50230303 Radiator cooler AP 300 2 E 24VDC TOTAL 40201880 Radiator cooling kit engine 22VDC W SQ6 RADIATOR COOLER KIT ENGINE 230VAC W SQ8 no att article no description 1 1 50230307 Radiator AP 430 230VAC W SQ8 2 2 50221502 Hose clamp stainless19 29 3 1 50221064 Male nipple 1 4 1 50221044 T stuk 1 5 2 50221014 Male hose connection 1x35 6 1 50221103 Straight reducer m f 1 3 4 7 1 50221004 Male hose connection 3 4x20 8 1 50212409 Temperature switch 87 82 degr 9 4 50201121 Vibration mounting 30x25 10 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexagonal SP M8 12 4 50211405 Washer SP M8 12 4 50211437 Washer mudguard SP 8x30x1 5 13 8 50211445 Washer spring SP M8 14 6 50220013 Hose vacum SAE100R4 11 4 31 8x45mm 15 4 50221504 Hose clamp stainless 38 50 16 8 50221597 Hose support SP 45x25 mm galvanised 17 1 50230529 Bracket expansion tank for 50230531 17 1 50230531 Expansion tank 20 mm 17 1 50230532 Cap tank 0502 30531 18 15 50220011 Hose vacuum SAE100R4 3 4 19x31 5mm 21 1 50221532 Hose clamp stainless mini 9 11 TOTAL 40201864 Radiator cooler kit engine 230VAC W SQ8 EN W SQ6 8 12 16 for mobile applications November 200
35. d run at low speed In this mode they almost produce no noise Only when necessary this is controlled by thermostat switches the fans are switched in parallel and will blow at full speed The same is achieved with 230 V fans with help of a transformer refer to the connection diagrams in paragraph 4 8 However when not strictly necessary we recommend using the standard fan control instead of the two speeds fan control in order to keep the system as simple as possible Y 2 5 3 Dry exhaust system 1 GENERAL REMARKS A dry exhaust muffler system should be very effective in silencing the exhaust when applying the right mufflers However noise could be generated by vibrations in the mufflers and be transferred to the chassis 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 Figure 25 Dry exhaust systems on vehicles 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 Rubbers are supplied to mount the mufflers flexible The insulation blanket 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 pi
36. ded in the standard supply A high efficiency battery charging unit can be ordered from Whisper Power which is able to charge both the vehicles s main battery and the starter battery Also a small charger can be used to charge the starter battery only such as the IVO SMART 12 10 A battery switch and a charger are included in the battery installation kits art no 40230210 70Ah or 40230220 160Ah 3 12V OR 24V DC TO DRIVE THE FAN When applying 12V or 24 V DC to drive the fan of the radiators the fan should be wired with minimum 4 mm2 cable according to the wiring diagram The negative return wire should be of the same diameter The return current should never be lead over the chassis The consumption of power by the 12V DC powered fan makes it necessary to install an additional 30 Amps battery charger to prevent the starter battery to be drained A much larger battery 170Ah at least is required The battery charging winding in the generating set is not capable of powering the fan Neither is the small charger that is included in the battery kit Whisper Power supplies high quality battery chargers that continuously supply the rated power Chargers of other suppliers are often rated to other standards and give the rated current Amps only for a short period if at all To avoid the need of an extra heavy battery charger a 230 Volt fan on the radiator is recommended One should realize that the power for the fan must be decucted from the
37. dy 0 ne 5 d 33 737 5 4 T ava n z I 2 1 5 EET wo pe E ef L DE E pe Ly daa m Se DE DT p Self is ER 1 Ova a Dium N ul u 3 gt zo 1 i 3 a T T 1 EA E m WI 1 ala E ame i i Zn ER E E 7 zd G J i y L Eau EE a x A 1 q sta E f M I T 1 a ma d 1 ES no Ll 1 1 z 3010 A 1 H H 8 m z i E 12 NE 1 d 1 S O d 1 E ol ze i E B Ex 1 15 dE a 8 ola ta 32 Flo E i 55 LG 1 1 Fa os ud i i T 8 wy h e 1 155 5 1 9 0 A 20 L 100 Fig 34 Layout generator control for W SQ6 8 and 12 with 230VAC radiator fan EN W SQ6 8 12 16 for mobile applications November 2008 33 IS Per Power wh DIAGRAMS amp DRAWINGS LAYOUT GENERATOR CONTROL FOR W SQ6 WITH 12VDC FAN 4 2 v 110N370S HOLI af ERE 7303 NBL SOLYS3N3 anak a HOLI HOLI 308YH usa GE dr ONAE sS3se MO IL Male
38. e DDC users manual especially to the APPENDIX 2 STARTER BATTERY For starting the Whisper requires a 12V starter battery with the following capacity Model Minimum capacity W SQ6 60Ah W SQ8 12 70Ah W SQ16 120Ah The generating set can be connected with the main engine battery or have its own battery We strongly recommend the use of a separate battery for the generating set and to keep the wiring system for the vehicle engine and the domestic DC supply system completely separate and individually connected to separate batteries 230VAC VO12 10 A di JL 42V Fig 31 Starter battery However the negative of all the batteries on the vehicle 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 vehicles having the starter battery of the vehicle engine or other auxiliary equipment positive grounded When this is the case an expert should be consulted A battery switch may be used to interrupt the positive connection The starter battery is charged by the alternator on the engine An additional battery charger will help to keep the battery in good condition when the generating set is not used 21 INSTALLATION 6 whisper Power A battery charger is not inclu
39. g 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 Figure 5 Mounting of the Whisper generating set 2 4 VENTILATION 2 4 1 General The generating set normally draws air from the engine compartment Engine compartment with natural ventilation must have vent openings of adequate size and location to enable the generating set 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 A sealed engine compartment must have a good extraction ventilator to maintain reasonable ambient temperatures High temperature of intake air reduces engine performance and increases engine coolant temperatures Air temperatures above 40 C reduce the engine power by 2 for each 5 C of rise To minimise these effects the engine room temperature must not be more than 15 C 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
40. he battery In the delivery are warning stickers to stick on A several parts of the electric installation transfer switch distribution box etc to warn for automatic start T Using the auto start stop interval mode the The Whisper Power Digital Diesel Control system offers several options for automatic starting and stopping Access to this menu and other menus could be blocked For de blocking and setting up this options refer to the APPENDIX of the DDC user s manual One of these options is to monitor a second battery not being the starter battery to start the generator automatically when the voltage of this battery drops below a certain setting Other names for this second battery are auxiliary battery service battery users battery or consumers battery We will refer to this battery as the second battery BAT2 In some menus the starter battery could be indicated as the first battery BAT1 EN W SQ6 8 12 16 for mobile applications November 2008 A sense wire to monitor the second battery should be connected attention polarity to the connector on the back of the remote panel Refer to fig 29 The sense wires must be connected directly on the second battery before a main switch and be protected by a 3 Amps fuse Monitoring the generator starter battery does not require an extra sense connection Settings When one want to apply other settings than the factory settings refer to th
41. he 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 generator engine should be avoided E LH Do NOT connect the fuel lines to the lines of the vehicles engine fuel supply A ad ud D Y Driving the tank empty below the level of the suction pipe of the generator could make it necessary to bleed the fuel system 2 FUEL LIFT PUMP The generating set itself is equipped with a fuel lift pump therefore the tank can be installed at a lower level than the generating set See figure 12 The maximum suction height is 1 m The W SQ16 has a mechanical fuel lift pump that should be primed manually when the first time used If the pump has to lift the fuel higher than one meter an external fuel lift pump must be installed Art No 50201060 The control board is already prepared to connect an extra fuel pump 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 will become quite hot and should be mounted out of touch Refer to fig 13 The pump makes clicking noises and therefore could be mounted on rubber mountings When the clicking noises of the pump are n
42. high voltage and dangerous to people Before working installation on the system read the sections on safety in the users manual Realise hat people are not used to have 230V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance personal of garages that do service on the vehicle Generators used on vehicles that are operated in a hazardous environment have often to fulfill special regulations and additional measures have to be taken accordingly gt bb Be sure that all electrical 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 onboard as the generating set itself cannot be equipped with such equipment for every possible variation The vehicle s 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 1 FUSE An output fuse between the generating set and the electrical installation should be installed to protect the installed electrical system The following maximum single phase output current applies
43. iagram fan control using 12V or 24V E n z 5 as eu 5 om E Fan EZ DC radiator fans optional EN W SQ6 8 12 16 for mobile applications November 2008 41 DIAGRAMS amp DRAWINGS whisper Power Y 4 10 WIRING DIAGRAM ELECTRONIC GOVERNOR STANDARD FOR W SQ6 8 AND 12 Fi g 42 Electronic governer In addition to the mechanical governor the W SQ6 8 and 12 are standard equipped with an electronic governor A governor keeps the speed RPM Rotations Per Minute of the engine at a fixed value The RPM of the engine correlates with the frequency of the electrical output 3000 RPM 50 Hz of the alternator Under full load the RPM of the Whisper models that have only a mechanical governor can drop 75 RPM 22 5 Hz at full load and will go further down or collapse when further loaded However the engines with the electronic governor will keep the RPM and frequency at the set value As the voltage is related to the frequency the voltage will be more stable as well The RPM represents power and the alternator performs better as well on a higher speed Whisper models with an electronic governor will bring more power So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The act
44. k 1 5 mm2 DDC gt fuel solenoid com 17 black 1 5 mm2 B terminal alternator gt starter motor 21 red 6 mm2 DDC gt R terminal alternator 18 wit 1 5 mm2 DDC gt L terminal alternator 19 orange 1 5 mm2 DDC gt current measuring transformer 11 black 1 mm2 DDC gt current measuring transformer 11 red 1 mm2 DDC gt LCP 12 black 1 5 mm2 DDC gt LCP 14 red 1 5 mm2 DDC gt LCP 16 red green 1 5 mm2 DDC gt generator AC output 33 brown 1 mm2 DDC gt generator AC output 33 blue 1 mm2 ENT W SQ6 8 12 16 for mobile applications November 2008 37 4 whisper Power DIAGRAMS amp DRAWINGS Y 4 6 WIRING COLOURS W SQ16 Cable code number colour cross section battery gt starter motor red 35 mm2 starter motor gt DDC 1 red 6 mm2 starter motor gt LCP 13 red 2 5 mm2 battery gt ground black 35 mm2 ground gt LCP ground GND 2 black 4 mm2 DDC gt glow plugs 3 brown 4 mm2 DDC gt starter solenoid 4 yellow 2 5 mm2 DDC LCD 5 grey 1 5 mm2 DDC gt oil pressure switch 6 purple 1 mm2 LCP gt oil pressure switch 6 purple black 1 mm2 DDC gt water temperature switch 7 blue 1 mm2 LCP gt water temperature switch 7 blue black 1 mm2 DDC gt exhaust temperature switch 8 blue green 1 mm2 LCP gt exhaust temperature switch 8 blue rose 1 mm2 DDC gt fuel solenoid hold 9 green 1 5 mm2 DDC gt fuel solenoid pull 20 pink 2 5 mm2 DDC gt fuel solenoid com 17 black
45. ke in the canopy is not blocked 5 Connect exhaust system 11 Check the oil level and colour of the oil Check the 6 Connect fuel supply line to the water separator fuel coolant level of both the alternator cooling and the filter engine cooling 7 Connect fuel return line to the fuel tank 12 To bleed the fuel system 8 Connect remote panel just plug in e W SQ6 8 and 12 push the Start button on the 9 Connect the AC cable from the AC box to the power local control not on the remote panel and hold source selector or Systemswitch at least 5 seconds and as long as necessary to 10 Connect plus and minus from the 12V starter battery bleed the system to the battery cables e W SQ16 use the manual pump by turning the 11 Connect the power supply of the radiators cap loose and pumping as long as necessary to 12 Install a Whisper Power battery charger optional bleed the system See chapter 4 2 2 of the user s manual 32 COMMISSION TABLE 13 Start the engine by pushing the start button 14 Check when the generating set is running the delay in th 1 Check if a hole for combustion air intake is in the Apul 19 eepondss E Powel BOMA sound shield Also check if an air inlet filter for ice f e A 15 Check voltage and frequency under no load combustion air is necessary and has been installed eae inane 2 Check the cooling system for the engine is properly TeBe A S e DES E V installed Note that air traps must be avoided GE oe EE
46. ler e Clamps and rubbers to mount the system flexible e Fittings bents and pipes to make the different connections e Blankets for thermal and sound insulation The mufflers are high quality industrial mufflers that are much more effective robust and durable than mufflers made for automotive use EN W SQ6 8 12 16 for mobile applications November 2008 3 INSTALLATION OF THE EXHAUST Before determining the location of the generator set one has to consider how to get away with the exhaust Often one can find space below the vehicle between the chassis to mount the mufflers The outlet should blow the fumes away from the doors to avoid a nasty smell When the gasses are in the flow of air blowing from the radiators this will help to avoid the fumes to be noticed Under no condition the fumes should be sucked into the flow of air into the radiators In wind still conditions a light smell of exhaust fumes around the vehicle will not be avoidable To bring the exhaust to the top of the vehicle gives the best results on noise and smell However when the pipes go through the vehicle they should be insulated and around the hole in the 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 below the vehicle In general it is better to have the mufflers wide apart the resonance muffler close to the generator and the absorption muffler on the end of the line A short pipe 80cm
47. ling M14 8 mm 44 2 50221644 Reducing male nipple M14 M16 60 gr 45 2 50221615 Hose connection 8 mm 46 2 50221616 Nut coupling M16x1 5 mm 47 1 50221252 Nipple hose pipe 8 mm 48 4 50221522 Hose clamps 10 16 mm 49 2 50221632 Gasket ring 14x20x1 5 mm TOTAL 40230205 FUEL KIT OPTIONAL INSTALLATION MATERIALS no aty article no description dimensions 50 1 50222020 copper fuel pipe 6x8 mm 51 1 50220063 fuel hose 8x16 mm 26 November 2008 W SQ6 8 12 16 for mobile applications EN INSTALLATION SPECIFICATIONS af supply Fig 32 Installation materials battery and fuel kit Included are all fittings to fit copper pipes 8 mm outer diameter or rubber fuel hoses 8 mm inner diameter or both EN W SQ6 8 12 16 for mobile applications November 2008 27 4 whisper INSTALLATION SPECIFICATIONS 5 EE DRY EXHAUST KIT 11 for W SQ6 8 12 and 16 no att article no description 61 1 50220043 Exh hose SS 500mm fem male 11 2
48. mm2 Coolant generator in Coolant engine in 10 November 2008 W SQ6 8 12 16 for mobile applications EN INSTALLATION Fig 10a Connections W SQ16 Fig 10b Connections W SQ16 EN W SQ6 8 12 16 for mobile applications November 2008 01 02 03 04 05 06 07 08 09 10 11 12 Expansion tank Z8mm Exhaust 17 Remote control AC power output Coolant engine out Coolant generator out Coolant generator in Coolant engine in Fuel in 8mm Fuel out 8mm Battery positive 35mm2 Battery negative 35mm2 11 INSTALLATION 6 whisver Power 2 5 1 Fuel supply 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 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 t
49. n 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 vehicle 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 bubbles The return pipe should never be connected to the suction pipe The return line should be of 8 mm diameter and go straight back via the top to the bottom of the tank When the return is too narrow has too many bents and goes back to the bottom of the fuel tank the back pressure could be too high This results in irregular running of the engine When the engine runs irregular one can 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 4 FUEL FILTERS A fine fuel filter is installed which requires maintenance Whisper Power 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 users manu
50. ocessor is in the delivery A 15 m intermediate 8 pole communication cable is in the standard supply as well refer to fig 28 If necessary an optional longer up to 30m 100ft intermediate cable can be connected if the standard length does not suit the required distance When a longer distance than 30m 100ft is required consult the Whisper Power service department for advice Fig 28 Remote control cable Y One can mount the control panel after drilling a hole in the dashboard using the plastic cover Refer to the dimensional drawings in chapter 4 The panel without the plastic cover fits the Mastervision modular panel system More remote control panels slave panels can be put in parallel by using the modular connectors on the back of the units As a slave one can use the same panel offering all functions again It is also possible to use an old or new type slave panel only to start and stop the generator Old type remote panels and system panels can be connected by means of the green connector When using the factory settings installation is very simple just plug the remote cable into the remote and the generator is ready to use Refer to fig 29 REMOTE CABLE T REMOTE CABLE gl WIRING COLOURS PF 1 RED L mom i Ae 4 YELLOW b ls 5 PINK b 6 PURPLE EE 7 BLUE L s 8 VWE le 9 ORE ble 10 GREY PINK boue 11 GREY Ch 12 BLA
51. ot acceptable another noiseless pump is available as an option Art No 50202200 2 Ie Fig 11 Fuel supply fuel tank is above the generating set 1 Fuel return 2 Fuel supply 3 Prefilter Water separator optional 5 Fuel Tank 12 November 2008 W SQ6 8 12 16 for mobile applications EN whisver Power INSTALLATION Tt Bt x S ic C eg 4 Fig 12 Fuel supply fuel tank is below the generating set 1 Fuel return 2 Fuel supply 3 Prefilter Water separator optional 4 Extra fuel lift pump optional 5 Fuel tank A aa 1 FUEL LIFT PUMP outlet horizontal inlet from tank y Figure 13 Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle EN W SQ6 8 12 16 for mobile applications November 2008 9 me 13 INSTALLATION 6 whisper power 3 FUEL PIPES When the tank is above the generating set figure 11 we recommend 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 we recommend ending the return line on the bottom of the tank A below the inlet of the supply line Both supply and retur
52. pe insulation blankets on other parts of the system and possibly even additional mufflers When the exhaust is led through the roof of a A vehicle measures has to be taken to prevent rainwater to enter the system Special rain caps are available as an option Figure 26 Ways to prevent water to get in 18 November 2008 W SQ6 8 12 16 for mobile applications EN whisper Power INSTALLATION Y A negative feature of a dry exhaust system is the heat radiated by its components Measures are taken to overcome the heat problem The exhaust bent to bring the exhaust out of the canopy is cooled by water Insulation blankets are included in the exhaust kit to insulate the flexible bellow and the first muffler When a dry exhaust has its outlet on the roof all the pipes inside the vehicle 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 2 THE STANDARD DRY EXHAUST SYSTEM The standard exhaust system contains On the generator set e Aninsulated exhaust bent In the exhaust installation kit e Astainless steel shielded flexible bellow e One resonance muffler e One absorption muff
53. rculation of the engine coolant gh p Ee po To Radiator Figure 16 Alternator cooling system open expansion tank with overflow pillar EN W SQ6 8 12 16 for mobile applications November 2008 For the alternator cooling system we use an open non pressurised system Therefore the 12 mm overflow pillar on the expansion tank should stay open figure 16 A piece of hose can be used to drain redundant liquid that is thrown out because of the expansion of the liquid in the system When open the expansion tank can easily release air that is ventilated by the different connections As the capacity of the alternator cooling system is very small also the initial filling can be done via the expansion tank It could be necessary to refill the tank a few times The pump of the alternator cooling system is self priming and this makes the system less sensitive for air traps For the engine we use a pressurised system The 12 mm connection on the top is closed Wherever the radiators are mounted it is necessary to ventilate the exhaust manifold of the engine The exhaust manifold has a 8 mm connection to ventilate the manifold There is an 8 mm high pressure and high temperature resistant hose in the delivery to connect the hose connection on the side of the manifold with the expansion tank refer to figure 7 till 10 Initially the engine cooling system can be filled via the cap on the exhaust manifold
54. re 19 detail B Y top mount Ir t Y Figure 19 Low profile radiator assembly on the roof Most cooling problems originate from air traps blocking the circulation of the engine coolant resistant hose and fittings Therefore it is strongly advised to use Whisper Power installation kits from Whisper Power T lt is very important to use good quality heat 16 November 2008 W SQ6 8 12 16 for mobile applications EN 4 whisper Power INSTALLATION SY 2 HOW AND WHERE TO MOUNT THE RADIATORS The radiator kit includes rubber mountings to prevent vibrations to be transferred to the body of the vehicle fig 20 Due to the difference between vehicles general instructions are not available One has to find out where the best place for mounting is For OEM customers Whisper Power can supply a special customised installation kit A ll 1 A 4 N be et Figure 20 Radiator on rubber mountings Bottom mounted radiators When bottom mounted the radiator should not be the lowest point of the vehicle to avoid damage A free flow of air should be guaranteed When horizontal mounted the fan should be on top which causes a flow of air downwards Often it is possible to find a place where extra space above the fan helps to create a free flow of air lt is recommended to make a shield below the radiator to catch stones
55. rland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl
56. se levels vibration etc the instructions set out in this manual must be followed and all installation work must be carried out professionally EN W SQ6 8 12 16 for mobile applications November 2008 2 2 LOCATION When looking for a proper place for a generator in a vehicle all relevant aspects have to be taken into account e Accessibility e Solid foundation e Space to mount the radiators Refer to par 2 5 2 e Space to mount the exhaust Refer to par 2 5 3 e Away to fit the fuel lines Since Whisper generating sets 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 generating set make sure there is sufficient room to carry out any maintenance work The unit must be easily accessible on the service side and on the distribution side to have access to the V belt All models can be serviced from one side Oil filling can be done on the service side and on the top except for W SQ16 that has the oil filler cap only on top Cooling liquid can be filled via the expansion tanks The top of the engine rocker cover has to be accessible for adjustment of the valve clearance Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level is checked regularly INSTALLATION 6 whisper Power 2 3 INSTRUCTIONS FO
57. tank 0502 30531 47 1 50230531 Expansion tank 20 mm TOTAL 40201888 Radiator cooling kit alternator 230VAC W SQ16 RADIATOR COOLING KIT ENGINE 230VAC W SQ6 no att article no description 1 1 50230304 Radiator cooler AP 300 2 E 230VAC 2 2 50221502 Hose clamp stainless19 29 3 1 50221064 Male nipple 1 4 1 50221044 TEE fitting 1 5 2 50221010 Male hose connection 1x25 6 1 50221103 Straight reducer m f 1 3 4 7 1 50221004 Male hose connection 3 4x20 8 1 50212409 Temperature switch 87 82 degr 9 4 50201121 Vibration mounting 30x25 10 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexogonal SP M8 12 8 50211405 Washer SP M8 13 8 50211445 Washer spring SP M8 14 6 50220012 Hose vacum SAE100R4 1 25 4x38mm 15 4 50221503 Hose clamp stainless 26 38 16 8 50221599 Hose support stainless 35x12 mm 17 1 50230529 Bracket expansion tank for 50230531 17 1 50230531 Expansion tank 20 mm 17 1 50230532 Cap tank 0502 30531 18 1 5 50220011 Hose vacum SAE100R4 3 4 19x31 5mm 21 1 50221532 Hose clamp stainless mini 9 11 TOTAL 40201879 Radiator cooling kit engine 230VAC W SQ6 30 November 2008 W SQ6 8 12 16 for mobile applications EN amp whisper Power INSTALLATION SPECIFICATIONS Y RADIATOR COOLING KIT ENGINE 12VDC FOR W SQ6 Same as article no 40201879 except no att article no description 31 1 50230302 Radiator
58. terials isos sso ata a 26 4 DIAGRAMS amp DRAWINGS ies ese EE SEE lonn RE AE Re ke NE SR RE oge Re Ee BARS AR RS SR KS ag EA ee Rg Dus eg Re Ee Ke eg ee De Oe EER ge 33 4 1 Layout generator control for W SQ6 8 and 12 with 230VAC Ton 33 4 2 Layout generator control for W SQ6 with 12VDC fan 34 4 3 Layout generator control for W SQ6 with 24VDC fan 35 4 4 Layout generator control for W SQ16 with 230VAC Tom 36 4 5 Wiring colours W SQ6 8 and 17 37 4 6 Wiring colours vase s inn eene s REL UE Ra e RE AER URS mene Ru 38 4 7 AG wiring diagram 230 A ET 39 4 8 Electrical diagram radiator fan control 230VAC nennen nnne nnne nnne nnns 40 4 9 Electrical diagram radiator fan control 12 24 VDL 41 4 10 Wiring diagram electronic governor Standard for W SQ6 8 and 19 42 4 11 Remote control_panel Es lass 2 ee Ee tcc AR ned alles ee EE Pee hee ene 43 4 12 Dimensions W2SQ6 RE RO ER RE EE AE OE ahlt 44 4 13 Dimensions WESQ8 ER i RR et OE OE ER N AE ET 45 4 14 BEE IER EE EE EE 46 4 15 Dimensions eh LEE 47 2 November 2008 W SQ6 8 12 16 for mobile applications EN Z whisper Power INTRODUCTION Y 1 INTRODUCTION 1 1 GENERAL This installation manual applies to the installation of Whisper gensets in vehicles This manual is valid for the following models Part number Description 41105020 W SQ6 230V 1500rpm Mobile 41105026 W SQ6 230V 1500rpm Mobile ungrounded 41106020 W SQ8 230V 1500rpm Mobile 41106026
59. uator controls the RPM directly on the fuel rack inside the fuel pump without levers and other mechanical transmissions 2 A microprocessor keeps the speed at the set value by controling the actuator The microprocessor is programmed at the Whisper Power factory and many parameters are set to perform well It should not be necessary to make adjustments When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor The Whisper Power electronic governor does not need a pickup device in the flywheel housing that counts the passing tooth of the flywheel and determines the exact RPM of the engine because the processor uses the 50 Hz of the AC output voltage as a reference 42 November 2008 W SQ6 8 12 16 for mobile applications EN whisver Power g DIAGRAMS amp DRAWINGS 4 11 REMOTE CONTROL PANEL DRAWINGS 128 ES Ee SS N M Ki 843 140 wo B 114 64 Fig 43 Whisper remote panel The remote panel comes in a carton that can be used as a template to drill the mounting hole EN W SQ6 8 12 16 for mobile applications November 2008 43 DIAGRAMS amp DRAWINGS 4 12 DIMENSIONS W SQ6 P L
60. ver from a land line to vehicle or from generating set to inverter should be well designed to switch over all wires including 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 Mass 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 A land line inverter and generator should switch both neutral and L1 Of course this is the case when using a Mass Systemswitch 23 INSTALLATION SPECIFICATIONS 6 whisper ower 3 INSTALLATION SPECIFICATIONS 3 1 GENERAL 8 Check all DC connections check if the battery switch 1 Make a hole for combustion air in the sound shield circuit breaker is closed Mount an air inlet filter if required 9 Open the fuel valve Check if there are no air leaks in 2 Mount the generating set directly without additional the fuel supply line and check if the lift of the fuel is vibration dampers on a solid surface less than 1 meter Check if there is no air in the water 3 Mount the cooling system for the engine fuel separator 4 Mount the cooling system for the alternator 10 Check if the air inta

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