WP-5012-002-01 DC Installation Manual - Off
Contents
1. TO FUEL OFF Labels Introduction and safety information Labels The WhisperGen is supplied with caution and warning labels affixed to it The labels and their locations are shown below Please ensure that Labels are not removed Installers and operators understand and comply with the instructions on the labels 1 Diesel Fuel Only Diesel fuel only hot temperatures inside DIESEL FUEL ONLY 4 Warning General HOT READ SURFACES MANUAL caution INSIDE BEFORE SERVICING Allin amp REMOVE COVER FOR SLING ACCESS 2 Serial Number Plate A CCA Pam WHISPERGEN Designed and Manufactured by WHISPER TECH LTD PO BOX 13 705 Christchurch N Z Patents granted and pending worldwide x en No 7XXX PPS16 24 5 Nitrogen Pressure Nitrogen pressure vessel and pressure settings NITROGEN ONLY A e WARNING PRESSURISED ASSEMBLY RELIEF VALVE 35BAR MAX FILL PRESSURE 28 BAR MAX AT 70 C 3 No Lift Do not lift the WhisperGen from this point LY NO LIFT M 6 Warning Primary Coolant Primary coolant circuit additives IN WARNING PRIMARY COOLANT CIRCUIT CONTAINS RESIDUES OF GLYCOL COOLANT DO NOT CONNECT TO POTABLE WATER CIRCUITS IN WARNING PRIMARY COOLANT CIRCUIT CONTAINS ALUMINIUM COMPONENTS ALWAYS USE A COMPATIBLE CORROSION INHIBITOR2. WHISPERG EN Personal Power Station Model PPS16 12MD and Model PPS16 24MD Part Number WP 5012 002 01 Whisper Tech reserves the right to revise or change product specifications at any time This publication describes the state of this product at the time of its publication and may not reflect the product at all times in the future Patents granted and pending worldwide Whisper Tech WhisperGen Personal Power Station and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited Title Installation Manual Models PPS16 12MD PPS16 24MD Part No WP 5012 002 01 Application WhisperGen PPS16 12MD Diesel fired 12 V DC output Marine WhisperGen PPS16 24MD Diesel fired 24V DC output Marine WhisperGen is designed and manufactured by Whisper Tech 224 Armagh St P O Box 13 705 Christchurch New Zealand www whispergen com Copyright 2005 Whisper Tech Limited All Rights Reserved Printed in New Zealand Conditions of use Read this manual completely before installing or operating the WhisperGen The WhisperGen must be commissioned only by an authorised WhisperGen representative Whisper Tech accepts no liability for personal injury or property damage resulting from incorrect or unauthorised installation commissioning and servicing of the WhisperGen Unapproved installations may be dangerous result in poor performance and void any WhisperGen warranty A
3. The control panel has AnLCD display that shows the operating state fault codes and performance values such as power output and heating temperature Start and Stop buttons Arrow keys for navigating menus Status lights An automatic backlight for the display that operates when a key is pressed and turns off after a few minutes of inactivity After 5 minutes of user inactivity the control panel reverts to the default screen If you need to go back to the default screen press the left arrow until the default screen is displayed 33 Fill and bleed the primary coolant system Prepare for commissioning Fill and bleed the primary coolant system Overview The primary coolant system must be filled and then the pump operated via the WhisperGen control panel to bleed air from the system Use only the specified coolant Use of incorrect coolant will result in corrosion to the WhisperGen Procedure When the coolant system is complete the battery bank is installed and all electrical wiring and connections have been made the coolant system can be filled and bled as follows 1 Remove the engine enclosure See Remove and re fit the enclosure on page 25 2 Fill the coolant system through the header tank with pre mixed distilled water and coolant additive See specifications and warnings on Primary cooling system boat heating system on page 12 3 From the default display on the control panel press Right Arrow to
4. 3 4 BSPT male x 3 4 hose tail fitting x 2 Flexible hose 19mm ID high quality marine grade Hose clips Marine grade stainless steel either permanently crimped or double hose clamps Seacocks and through hull fittings High quality marine grade to suit the vessel Other components One way valve marine grade to suit hose size required if sharing a raw water supply with other equipment Strainer filter marine grade to suit hose size The secondary cooling pump should Be suitable for use with sea water Provide the specified flow rate See Operational specifications below Be self priming Be compatible with Pulse Width Modulation control The final pump size is determined by the pressure drop within the system This is a combination of pressure drop through the various system components pipe length pipe diameter and vertical rise Contact your WhisperGen agent or a pump specialist to correctly size the pump for the particular vessel installation Do not oversize the pump as it would increase the rate of flooding if a leak develops in the secondary coolant circuit The pump should be located above the waterline in a position immediately upstream of the WhisperGen Through hull fittings and seacocks should be installed prior to WhisperGen installation by a tradesman suitably experienced to carry out such work All through hull fittings must be installed in accordance with ISO 9093 1 and
5. Introduction and safety information Compliance information Compliance information Responsibility for compliance It is the responsibility of the person s installing the WhisperGen and its systems to ensure that it is installed in compliance with all laws standards and regulations that apply in the country where the WhisperGen is installed The installer must determine what laws and regulations apply European CE mark and The WhisperGen is CE marked for applications where it is installed in installation standards for recreational craft This means that in such an installation the WhisperGen recreational craft installations complies with the Essential Health and Safety Requirements of the relevant European Commission Directives which are Machinery Directive 98 37 EC Electro Magnetic Compatibility Directive 2004 108 EC Pressure Equipment Directive 97 23 EC Waste Packaging Directive 94 62 EC The installation of the WhisperGen must comply with the Recreational Craft Directive 94 25 EC and the Amending Directive 2003 44 EC This manual provides information to help the installer comply with the installation requirements of the Recreational Craft Directives Although the WhisperGen itself is not included in the scope of these Directives it has been developed so that it can be installed in accordance with them The Recreational Craft Directive harmonised standards relevant to the installation of the WhisperGen are S
6. Pressure Equipment Directive 97 23 EC 39 Appendices WhisperGen DC Marine Installation checklist WhisperGen DC Marine Installation checklist Complete this form and send it to your WhisperGen supplier who will arrange for an authorised WhisperGen representative to commission your WhisperGen Vessel name Port of registration WhisperGen serial number Vessel owner name Vessel owner phone number Vessel owner email Vessel owner address Installer name Installer phone number Installer email Installer address Name of WhisperGen supplier Check Page v Check Page Electrical system Secondary coolant system All controls amp sensors installed 30 Components meet specification 18 The battery bank installed 24 System laid out correctly 18 No load connected between the current shunt and battery 30 P System pied 2e Fuel system Exhaust system Components meet specification 9 Components meet specification 21 System laid out correctly 9 System laid out correctly 21 System leak tested 28 System leak tested 28 System bled 37 Condensate drains all low points 21 Primary coolant system Drains include water seal air trap 21 Components meet specification 12 Compliance with regulations System laid out correctly 12 Installer certifies that all regulations met 5 Header tank at highest point 12 Pre
7. Additional space heating over 5 5 kW large heating circuit and or existing installation Kits required Base kit plus 12 V supplementary kit or 24 V supplementary kit Space heating supplementary kit Also requires purchase of Base kit plus 12 or 24 V supplementary kit Part number WP 5011 007 00 WP 5011 008 00 WP 5011 009 00 WP 5011 010 00 See Primary cooling system boat heating system on page 12 for descriptions of the different heating options Select a site for the WhisperGen Design and plan your installation Select a site for the WhisperGen Requirements Minimum clearances Key 1 2 3 Minimum 150 mm for cover removal and removal of FID Minimum 300 mm for service access Allow at least 100 mm between the back of the WhisperGen and the hull or wall for pipework and fittings The WhisperGen must be mounted on a surface that is Clean Dry Level Flat Strong and rigid enough for the expected loadings Impervious to diesel fuel and water The WhisperGen should be located In an area with an ambient temperature range of 10 C to 40 C In an area separated from living or accommodation spaces If installation in a living space is necessary a sealed compartment should be used with adequate ventilation from outside the living space Where there is adequate ventilation and supply of air for combustion Away from magnetic compass navigational
8. Primary cooling system boat heating system Design and plan your installation Primary cooling system boat heating system Overview of the entire coolant system Key Exhaust heat exchanger Core engine Clamp element heater Generator housing Marine heat exchanger Secondary cooling in Secondary cooling out Primary coolant in Primary coolant out oO NP O Overview of the primary coolant circuit The engine coolant system can be used to provide cabin heating and potable water heating for the boat An electrical element clamp element is built into the WhisperGen internal coolant circuit to provide extra heating capability if the battery bank is charged and the WhisperGen is being operated for heating purposes This element is operated by the microprocessor All internal coolant piping on the WhisperGen is complete with both primary and secondary coolant circuit inlet and outlet connections located at the back of the machine The primary coolant circuit is a self contained fully pumped circuit It can be sealed or sealed and pressurised Open vented systems are not recommended It uses treated coolant to provide corrosion protection for critical engine components Coolant is pumped from a header tank to the WhisperGen where it passes through the primary side of the marine heat exchanger to remove any excess heat The coolant then passes through the clamp element heater generator housing and
9. access the menus User Menu 4 Press Down Arrow to scroll down to the Installation Menu Installation Menu 5 Press Right Arrow to access the Installation Menu 6 Press Down Arrow to Coolant 1 Bleed Coolant 1 Bleed 7 Press Right Arrow to edit the setting Press Up Arrow turn Coolant 1 Bleed ON See Step 11 for instructions for turning the Coolant Bleed to OFF Coolant 1 Bleed ON After 5 minutes of user inactivity the control panel reverts to the default screen If you need to go back to the default screen before this press Left Arrow until it is displayed 8 Slowly unscrew the bleed valve on the exhaust heat exchanger until air free coolant runs from the bleed See picture below Bleed valve 34 Prepare for commissioning Fill and bleed the primary coolant system 10 11 12 Bleed any other air bleed devices installed in the system in the same way starting with the lowest point in the system Make sure there is sufficient flow through the header tank The flow should be minimum 6 L min and should create a visible surge effect in the tank Turn Coolant 1 Bleed to OFF To do this From the default screen on the control panel press Right Arrow to access the menus Press Down Arrow to get to the Installation Menu Press Right Arrow to access the Installation menu and press Down Arrow to Coolant 1 Bleed Press Right Arrow to edit the setting and press Down Arrow to turn Coo
10. secured by the clamp and are not inserted under the clamp by mistake Battery terminals Battery cable Battery cables cut back by at least 25 mm 32 Prepare for commissioning To operate the control panel Prepare for commissioning To operate the control panel Overview To prepare the WhisperGen for commissioning the primary and secondary cooling systems and the fuel system must be filled and bled of any air pockets This requires operation of the pumps which are controlled from the WhisperGen control panel Make sure that the engine enclosure is tightly secured at all times when operating the engine or ancillary equipment See Remove and re fit the enclosure on page 25 No attempt should be made to run the engine before commissioning To do so may damage the engine and invalidate the warranty The Control Panel The control panel is the main interface between the user and the WhisperGen The control panel allows the user to start and stop the WhisperGen change settings and view performance It alerts the user to system faults and allows access for commissioning and service At this pre commissioning stage the only functions required are in the Installation menu Key 1 Start button u LZ 2 Arrow keys ZI WHISPERG EN 3 Status lights O STANDBY FAULT O STARTING AUTOCHARGE O RUNNING EXT CONTROL O STOPPING HEAT MANAGE O A E START lt o STOP 9 zs A SIDE
11. and the distribution board ve The battery bank provides an electrical buffer for the varying loads required When planning the location and installation of the battery bank relative to the WhisperGen take into account the guidelines below and the electrical connection requirements on page 30 If the battery bank is used to operate essential services provision must be made for an alternative charging source and or additional reserve battery capacity Battery bank Good quality deep cycle marine battery bank For 12 V DC a minimum 200 amp hour capacity For 24 V DC a minimum 100 amp hour capacity Battery bank cables For 12 V DC size 50 mm maximum length 8 m For 24 V DC size 35 mm maximum length 8 m Longer distances can be achieved with larger diameter cable Consult an expert for advice on correct sizing Battery bank cable lugs Sized to suit cable diameters and battery terminal type Battery bank terminal covers To suit battery terminal type When installing the battery bank make sure that There is adequate constraint for anticipated vessel movement There is containment of leaking or spilled electrolyte The mounting equipment to the battery bank is resistant to battery electrolyte The distance between the battery bank and sources of heat is adequate The battery bank is covered and protected from possible electrical short circuiting There is adequate ventilation fo
12. core engine before passing through the exhaust heat exchanger Now at a state of highest temperature it exits the WhisperGen and may be used to Option 1 Heat just the potable water supply Option 2 Heat the potable water supply and up to 5 5 kW of space heating Option 3 Heat the potable water supply and through an additional heat exchanger provide supplementary heat to a separate space heating circuit greater than 5 5 kW Configuration requirements for each of the three heating options follow 12 Design and plan your installation Primary cooling system boat heating system Option 1 Potable water heating only Key Header tank Pressure relief valve 100 kPa Stopcock Filter min 100 micron Coolant pump Water heater Calorifier ooAs om Option 2 Potable water heating and up to 5 5 kW space heating Key Header tank Pressure relief valve 100 kPa Stopcock Filter min 100 micron Coolant pump Water heater Calorifier Radiators air water heater Room thermostat ONOOPAN gt When the WhisperGen is in Battery Charging mode it can provide sufficient thermal energy to heat a large quantity of potable hot water The WhisperGen can be connected to a thermostat in the calorifier or hot water cylinder so it will start and stop on command from this thermostat The WhisperGen primary coolant circuit can directly supply hot water for space heating of up to 5 5 kW provided the total len
13. devices For installations near such devices the devices must be compensated for any magnetic or electrical influences With minimum clearances as shown 650 300 mm The air intake is located underneath the enclosure base and must remain unrestricted at all times If the WhisperGen is located in an enclosed area a minimum 20 cm opening must be provided to allow fresh air to the WhisperGen Use the WhisperGen fixing template to correctly mark the fixing points on the floor The control panel needs a wall that is clean and dry with access behind it so that it can be mounted The wall should be between 1 5 and 15 mm thick Design and plan your installation Fuel system Fuel system Overview of the fuel system Component specifications General requirements The fuel system for the WhisperGen must consist of A fuel tank and fuel pick up An isolation valve A filter A water separator this may be combined with the filter Afuel pump supplied with the WhisperGen and Suitable piping and fittings Correct flow and pressure of fuel to the WhisperGen is essential for its operation and can be affected by the diameter and length of the piping used and by the location of the components in the line Meeting the component specifications and design guidelines below will result in a safe and effective fuel system Fuel type Automotive diesel
14. exchanger and down the entire length of the exhaust pipe under all operating conditions and must be removed The WhisperGen incorporates a condensate drain point however any other low points in the exhaust system must also incorporate drain points Low points in the exhaust may occur when the boat is on a heel and these must be planned for and drains installed accordingly Where possible a 10 fallback to the WhisperGen and other condensate outlets is desirable Each condensate drain must prevent exhaust gases leaking into the vessel Where the drain is into an open waste water system or other collection disposal point a water seal type air trap must be used as shown in the diagram below Each fu N condensate drain tube A er en N must contain a water seal lt M air trap to prevent SS ar a exhaust gases leaking pes a into the vessel The tube must contain a 150 mm diameter loop with a water seal 1 iti o Operational specifications Max temperature under normal operating conditions Max temperature under an extreme fault condition 150 C Back pressure max 7 mm H O at 70 C Warnings and cautions Exhaust fumes can cause illness and death Make sure that exhaust gases are vented outside enclosed areas at all times Avoid condensate contact with skin and eyes Wear protective clothing when dealing with condensate 22 Design and plan your installation Fresh water flushing Fresh water flushing Over
15. living Spaces Exhaust outlet The exhaust outlet must not be positioned within 500 mm of a refuelling fitting or tank vent The exhaust outlet must ensure that All combustion products are ducted to the outside Re entry of combustion products through openings into accommodation spaces is minimised The exhaust is protected from wind gusts back drafts and water by a weather cowling The exhaust is not able to be submerged at any time not even momentarily including when the vessel is being reversed An external outlet to stern is preferable on a mono sail or motor launch The outlet can be between hulls on a catamaran Bend in pipe to prevent backwash from exhaust outlet WhisperGen ra M O A Exhaust outlet EU with suitable a cowling c Transom s 21 Exhaust amp condensate drain Design and plan your installation Back pressure length and The system must be designed to minimise back pressure The minimum diameter design exhaust pipe size is 32 mm ID If the exhaust exceeds 4 m in length the back pressure of the exhaust should be measured with a manometer to ensure that it is less than 7 mm H20 at 70 C Consult your WhisperGen representative if you are unsure To minimise back pressure keep the number of bends to a minimum and do not use corrugated hose Do not install dampers or shut off valves in the exhaust Condensate drain points Condensate forms in the exhaust heat
16. of the outlet close the outlet seacock Remove the outlet hose and observe flow into a bucket 10 Once the required flow is achieved turn Coolant 2 Bleed to OFF To do this From the default screen on the control panel press Right Arrow to access the menus Press Down Arrow to get to the Installation Menu Press Right Arrow to access the Installation menu and press Down Arrow to Coolant 2 Bleed Press Right Arrow to edit the setting and press Down Arrow to turn Coolant 2 Bleed OFF 36 Prepare for commissioning Bleed the fuel system Bleed the fuel system Overview Procedure Bleeding the fuel system requires the opening of the fuel valves diversion of the fuel line into an appropriate container and operation of the fuel pump from the control panel until the fuel flows clear of debris and bubbles To bleed the fuel system 1 Turn the fuel switch on the front of the WhisperGen to ON 2 Make sure the isolation valve at the fuel tank is OPEN 3 Disconnect the fuel line from the evaporator See Identification of main components on page 3 4 Connect a clear plastic hose to the exposed end of the fuel line and put the end of the hose in a bottle or other container suitable for holding fuel 5 From the default display on the Control panel press Right Arrow to access the menus User Menu 6 Press Down Arrow to scroll down to the Installation Menu Installation Menu 7 Press Right Arrow
17. torque 27 Connect fuel and plumbing fittings Install the WhisperGen Connect fuel and plumbing fittings Overview Connection points Key A Primary coolant IN Nylon type 3 4 BSP Female B Primary coolant OUT Brass type 3 4 BSP Female C Secondary coolant IN Nylon type 3 4 BSP Female D Secondary coolant OUT Nylon type 3 4 BSP Female E Condensate drain Stainless steel type 1 2 OD Stub F Fuel inlet Brass type 1 8 BSP Female Fresh water inlet Nylon type 3 4 BSP Male H Exhaust outlet Stainless steel type 1 1 4 BSP Female J Electrical glands 3 x 5 8 Connection seals Leak testing Fuel and plumbing systems can be connected to the WhisperGen after the systems have been installed brought to the WhisperGen installation site and the final positioning of the WhisperGen relative to the service connection points has been tested It is important to ensure that the connection fittings on the systems are compatible with the size and type of connection points on the back of the WhisperGen as described below The service connection points on the WhisperGen are shown in this diagram k O4 r 200 155 7 110 S 850 tile 9 Qs i999 17 60 Ar 120 140 170 Elbow fittings may be required on installations where there is insufficient room from straight connections Seal all nylon type connection
18. use the WhisperGen Whisper Tech does not convey any right title or interest in its intellectual property including without limitation its patents copyrights and know how No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Whisper Tech Every effort has been made to ensure the accuracy of this document however it may contain technical inaccuracies or typographical errors Whisper Tech assumes no responsibility for and disclaims all liability of such inaccuracies errors or omissions in this publication Use of the WhisperGen shall constitute your acceptance of the conditions above Contents Introduction and safety information unnssrssnnnnennnnnennnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnsnnnnnnsnnnnnnnnnnnnnsnnnnnnsnnnnnnnsnnenensnnnnnnnnnnnnn 1 Overview ofthe WhisperGen oat e can ale RERO OE RATE UH dete 1 Purpose of this manual yenin ene Ute o te sede tat Be eed 1 Importance of correct installation nisin inaina aa aE Ea Aa Ae a nennt enne anser ene tet enses nnns 2 Symbols in this manual sss siad petto te el t ae pertes aie boat esu rre Cedo D Lee Rid 2 Emergency procedures Gp MORE ER Dre EROR RERO REIR ROREM TERR R ORARE RR eres 2 Normal Operations cecil Be ee ee eid nce es te eee 3 Identification Of main components eene nennen nennen ener nennen enn ner nennen nnn nennen nns 3 ucl 4 Compliance informa
19. BS2869 1998 burner fuel class C2 Fuel filter and water separator Bowl type combined filter water separator Max 10 micron element Min 1 L hr flow rate 200 kPa max pressure Connection to suit fuel line 3 2 mm ID Fuel line metallic tube Seamless annealed copper stainless steel or equivalent 3 2 mm ID Fuel line flexible hose Fire fuel and chemical resistant SO 7840 type A1 or A2 UL 1114 or SAE J1527 hose 3 2mm ID Hose clips for fuel hose do not use spring clamps Stainless steel 8mm nominal width Isolation valve Appropriate fuel standard isolation valve with fittings to suit line diameters The fuel system must be permanently installed and all component parts with the exception of small connectors and fittings must be supported individually All fuel system components must be installed above the anticipated bilge water level The fuel system needs an ambient temperature range of 10 C to 80 C The WhisperGen requires a dedicated fuel supply directly from the main fuel tanks Do not tap off existing fuel lines to supply the WhisperGen All fuel system components individually or as an installed system must be able to withstand a 2 5 minute fire test in accordance with the Recreational Craft Directive and its harmonised standards See Compliance information Fuel system Design and plan your installation Fuel system layout Fuel tank and pick up Fu
20. DU e ON Overview of the secondary cooling circuit Key Inlet seacock One way valve if required Strainer filter Secondary cooling pump self priming Outlet seacock oc RON The engine coolant system can be used to provide cabin heating and potable water heating for the boat An electrical element clamp element is built into the WhisperGen internal coolant circuit to provide extra heating capability if the battery bank is charged and the WhisperGen is being operated for heating purposes This element is operated by the microprocessor All internal coolant piping on the WhisperGen is complete with both primary and secondary coolant circuit inlet and outlet connections located at the back of the machine The secondary system is an open pumped total loss system Sea water is circulated through the secondary side of the integrated marine heat exchanger before being dumped overboard This removes any surplus heat from the WhisperGen primary coolant circuit The pump speed is determined by the engine temperature and regulated automatically by the WhisperGen via a variable speed output 18 Design and plan your installation Secondary cooling system seawater heat dump circuit Component specifications Secondary cooling pump Through hull fittings Secondary cooling pump 12V DC for 12 V models 24V DC for 24 V models See further requirements below Hose fittings
21. O 7840 2004 Small craft Fire resistant fuel hoses ISO 9093 1 1994 Small craft Seacocks and through hull fittings metallic SO 9093 2 2002 Small craft Seacocks and through hull fittings non metallic SO 9094 1 2003 Small craft Fire protection for a hull up to 15 m in length ISO 10088 2001 Small craft Permanently installed fuel systems and fixed fuel tanks SO 10133 2000 Small craft Electrical systems Extra low voltage DC installations ISO 10240 1995 Small craft Owners manual SO 16147 2002 Small craft Inboard diesel engines engine mounted fuel amp electrical components Explosive environments The WhisperGen is not suitable for installation in spaces or compartments that require ignition protected equipment Introduction Design and plan your installation Design and plan your installation Introduction The WhisperGen is at the heart of a recreational marine power generation and heating system that varies from vessel to vessel depending on customer requirements and the vessel configuration The equipment supplied on page 6 with the WhisperGen and the optional installation kits on page 7 comprise only part of the overall system Safe and effective operation of the WhisperGen requires that all parts of the system are correctly designed and installed This section has essential design and planning information on The equipment supplied with the WhisperGen The opti
22. WhisperGen stop the WhisperGen immediately and ventilate the area To isolate the WhisperGen from the battery bank Open the circuit breaker and remove the in line fuse from the voltage sense wires Isolating the WhisperGen from the batteries while the WhisperGen is running will result in engine damage and void the warranty If a fire occurs Use a CO or Dry Powder fire extinguisher DO NOT USE WATER Use of water on diesel or electrical fires can result in explosion burns and electrical shock Introduction and safety information Normal operation Normal operation Only run the WhisperGen after it has been commissioned by an approved WhisperGen agent Attempts to run the WhisperGen before commissioning may damage the engine and void the warranty Under normal operating conditions you should run the WhisperGen with the main enclosure cover firmly in place Do not run the WhisperGen for more than five minutes with the cover removed Identification of main components The main components of the WhisperGen are identified in the diagram below They are referred to throughout the manual Key d Fuel evaporator assembly Air intake Burner assembly Exhaust heat exchanger Lifting lug Terminal block Electronics enclosure Main enclosure cover Fuel valve 0 Control panel 00 N orn OWN EXEC visa cene
23. arator If the bottom of the tank is positioned below the filter separator then a raised day tank with integral lifting pump and demand or float valve is required The fuel pick up in the tank s must be installed to ensure fuel availability at all angles of heel The isolation valve must be positioned at a maximum 200 mm from the tank The fuel pump should be Mounted between 45 and vertical Supported independent of the fuel lines Isolated from the vessel structure by rubber mounts Mounted away from the battery bank Oriented in the direction of the arrow on the pump 10 Design and plan your installation Fuel system Fuel system connections Connections or joints between rigid lines must be made with screwed compression cone brazed or flanged joints All flexible fuel lines must be secured to component studs with a metal hose clamp or a permanent fitting such as a swaged sleeve or threaded insert All rigid fuel lines must be supported at 300 mm spacings and within 100 mm of connection to a flexible line Do not use clamps that rely solely on spring tension Adequate precautions must be taken to prevent accidental spillage or discharge of pollutants such as fuel and anti freeze into the bilge or overboard All work carried out and components used as part of the WhisperGen fuel installation must comply with the Recreational Craft Directive on page 5 and its harmonised standards 11
24. are routed through the three electrical glands at the rear of the WhisperGen Once the cables are fed into the enclosure route them to the terminal block on the left side of the electronics enclosure Ensure there is sufficient slack in the cables to avoid strain on the terminals to allow for re termination if required and to allow for the WhisperGen to be moved if access to the rear is required ext digital OUT ext digital IN current shunt voltage sensor battery temperature sensor secondary coolant pump aux DC output fuel pump primary coolant pump battery bank WhisperGen ELECTRONICS CIRCUIT BREAKER 150A Positive DC supply to distribution board BATTERY BANK BATTERY TEMPERATURE SENSOR 30 Install the WhisperGen Connect the electrical power and control wiring ve ve Function Specification Procedure 1 Not used Ext Digital OUT optional 5V maximum 100mA digital output suitable for the digital control of an external device such as an additional water heater Physical or dry contacts Not suitable to drive relays Ext Digital IN optional Digital input for enabling an external switching device for example a hot water thermostat or timer that is used to start and stop the WhisperGen Relay only Clean contact Do not apply voltage across these terminals 7 Do not apply voltage Current Shunt Battery bank current sensor mount on the dis
25. e Water or steam will not discharge onto the occupants of the vessel or cause damage to the vessel or electrical components and wiring Primary coolant pump The coolant pump must be sized to provide sufficient flow rate and pressure to overcome the pressure drop for the complete coolant heating system Install the coolant pump immediately upstream of the WhisperGen with suction connected directly to the header tank Keep the distance between the header tank and the pump suction to a minimum Hot water cylinder calorifier If the hot water cylinder thermostat is used to start and stop the WhisperGen then it must be set to 5 C below the WhisperGen temperature setpoint Cabin heating Cabin heating can be by radiator or fan heater Interconnecting pipework All interconnecting pipework must be in accordance with all local laws and regulations The minimum recommended pipe size is 19 mm ID diameter Install air bleed valves at any high points in the system and a drain valve at the lowest point By pass circuit If the room heating or calorifier heating flow is controlled by thermostatic valves a by pass circuit must be installed to allow coolant to circulate when heating is not required If the water flow cannot be maintained during engine shutdown the WhisperGen can overheat To overcome this use one of the following options Install a by pass valve over the calorifier valve This will ensure that the water flow is maintained o
26. e opening 5 Fitthe supplied clamp washer and nut onto the control panel and tighten the nut until the control panel is secure Handle the control cable connection with care It is sensitive Do not attempt to start the WhisperGen before it has been commissioned by an authorised WhisperGen agent 29 Connect the electrical power and control wiring Install the WhisperGen Connect the electrical power and control wiring Overview Cable route Connection instructions SECONDARY SEAWATER PUMP PRIMARY COOLANT PUMP Negative DC supply to DC bus appliances inverter etc CURRENT SHUNT Do not connect any external loads or other generation sources between the current shunt and the battery bank Ancillary equipment such as the battery bank pumps and current shunt are wired to the terminal block on the electronics enclosure All external wiring is low voltage 12 or 24 V DC to the battery bank and associated sensors only All electrical work must be carried out by suitably qualified personnel in accordance with all local regulations and laws Minimise battery bank related safety hazards by ensuring that the battery bank is installed in accordance with marine practice BEFORE the WhisperGen is connected and run All wiring must be securely clipped independent of pipelines and fuel lines No terminating electrical connections are to be installed within 300 mm of the fuel line or pump Power and control cables
27. eeeesceceeeececeesesteeeedeneneeteseeneneseneceseegeeeseneseeseseeseesseeeeessensesseansenteseeeers 25 Lift tneWhisper en 2 2 2122 ee ellie caer divi Li OT tne beats 26 Attach the exhaust heat exchangel ccccesenceceseeceeeeeeeeeeesenseeeeseeceeseseeeeseseesesesseeeessaeeesesasenesenseeseseneeseseasentegs 26 Fixthe WhisperGen into position ceni enint teens D decere tes oce een 27 Connect fuel and plumbing fittings sessiessessesseeeeeeeseneenen nennen nne entnehmen nnne tenen nnne tnnt nnne nnn nnne 28 Install the controlpanel ennnen Ee t cete eee vcre dee Er 29 Connect the electrical power and control wiring nennen nennen nennen 30 d 10 UR o1 diee LLLICCI D Ir 33 To operate the control N 07 1 17 1 KERFFERERHFIPLPERSERREFETFERFPEFFTERPFRFFEERPERTEFERRERTERUEETTERFFEREFEFPFEFLTFSESEEERTREFEREEEFRTRFFEFEREFERFERFEREELFERFFEEER 33 Fill and bleed the primary coolant system u uneseessnnnnenennnnnnnennnnnnnnnnner nennen nnnnnennennnnerernnnnennnnnnnnnnnnerennnnennnnnnnnenn 34 Bleed the secondary cooling system 244044444440RHnnBn0nnnnnnnnnnnnnnnnennnnnnenennonnnnnnnennersnnnmennnnornnsnennennnannen none 36 Bleed thef el syStem repe bed hi tain t o RU D REIR D E ec ie ce o ee dr ee 37 Appendices eadein amaaa aaa trac ir vain Rua a S Ti YEN US LN EE GER wa DE aaa 38 Transporting by land Om alb i o et e Ee iC ESO EROR IIR IM GA DE AUR 38 Technical specificat
28. el pump A correctly laid out fuel system will ensure A free flow of fuel i e gravity fed at the rate of 1 litre hour to the fuel filter separator under all boat operating conditions The fuel pump is no more than 300 mm from the filter The WhisperGen is positioned no more than 6 m in total and 1 25 m vertically above the fuel pump Draw a scale diagram of your fuel system layout and ensure it meets these requirements before starting your installation The layout sequence starting from the fuel tank is 1 Fuel tank and pick up 2 Fuelisolation valve Max200 mm from the fuel tank 3 Daytank and integrated lifting pump only required if the fuel tank pick up is lower than the fuel filter separator 4 Fuel filter separator Minimum free flow at filter of 1 litre per hour Maximum distance from the fuel tank is 5 m if using a 10 mm ID line Greater lengths can be achieved using larger diameter lines 5 Fuel pump Maximum distance from the filter is 300 mm ID of the line must be 3 2 mm 1 8 6 WhisperGen Maximum length of line from the pump to the WhisperGen is 6 m Maximum rise from the pump to the WhisperGen is 1 25 m ID of the line must be 3 2 mm 1 8 The fuel tank must be positioned so that the fuel pick up either from the bottom of the tank or via stand pipe and siphon is not lower than the fuel filter separator i e there must be a free flow of fuel to the filter sep
29. fitted with seacocks The inlet fittings should be positioned to ensure The inlet remains below the water line at all times The inlet is not subject to turbulence when the vessel is under way Fittings that extend through the hull must not affect the integrity of the hull The discharge for the secondary coolant system should be located below the waterline a minimum of 2 0 m from the inlet It is a good idea to have the inlet and outlet on opposite sides of the keel This will avoid hot water pooling when moored in quiet waterways 19 Secondary cooling system seawater heat dump circuit Design and plan your installation Pipelines and in line fittings Operating specifications Warnings and cautions All pipelines and fittings must be installed to minimise pressure drop and prevent airlocks If the secondary cooling circuit is to be connected to a shared raw water supply then a one way valve should be fitted on the inlet side This will ensure that the WhisperGen secondary system always has water in it The pump must be protected from the induction of debris by way of inline filter or strainer fitted between the pump and the one way valve All connections must be fitted with two hose clamps Flow rate min max 6 11 I m Pressure drop across heat exchanger 10 kPa 10 l m Max allowable pressure inside heat 100 kPa exchanger Pump max electrical load 50 Watts Be careful when installing pipes and
30. fittings If the seawater coolant pipes and or fittings fail the vessel could flood If possible the WhisperGen should have its own inlet and outlet for the secondary coolant system 20 Design and plan your installation Exhaust amp condensate drain Exhaust amp condensate drain Overview of the exhaust WhisperGen requires a dedicated low back pressure exhaust system that carries exhaust gases safely overboard whilst avoiding the build up of condensates at low points in the system Component specification Exhaust tubing 32 mm ID minimum marine quality exhaust tubing Exhaust outlet cowling As necessary to protect the exhaust outlet from wind and wave action Condensate drain tubing and clips Good quality clear chemical resistant reinforced 13 mm diameter All materials used in the exhaust system must be marine grade resistant to salt water oil and combustion products and must maintain integrity at temperatures up to 200 TC Exhaust route The exhaust system must be continuous and sealed from the WhisperGen to the point of discharge Donot connect the WhisperGen exhaust system into other exhaust systems Do not connect other discharges into the exhaust All parts of the exhaust system must be accessible for inspection Piping and components must be supported to minimise the risk of failure from vibration shock expansion and contraction The exhaust system must not pass through accommodation or
31. gth of the circuit is less than 15 m In this configuration do not use a thermostat to control WhisperGen operation as it would result in frequent stop start cycling of the unit leading to excessive cabin heating temperature fluctuation Instead use thermostatic valves or switched fans on the boat heating system radiators 13 Primary cooling system boat heating system Design and plan your installation Option 3 Over 5 5 kW heating requirement Key Header tank Pressure relief valve 100 kPa Stopcock Filter min 100 micron Coolant pump Water heater Calorifier DON For larger heating systems and extended cold climate operation it is strongly recommended that a separate purpose designed heating system be installed Option 3 is also recommended for existing heating systems i e not new installations The heating system should be isolated from the WhisperGen by the use of a suitable heat exchanger available from your WhisperGen agent in the optional installation kit on page 7 The WhisperGen will act as an auxiliary heater when it is charging the batteries thus augmenting the main water heater The heating unit and pump in the separate heating system can be controlled by a room thermostat In the warmer months when heating is not required the system can be left in standby mode and because it is isolated from the WhisperGen will not affect the WhisperGen s operation 7 Heat excha
32. he same voltage rating as the WhisperGen and that it is suitable for operation with a PWM output The combined load on the AUX DC and EXT PWM outputs must not exceed 12 amps Aux DC Output 120r24V Used to power any external equipment that is switched by the WhisperGen 17 Fuel Pump Connect the fuel pump ve lead yellow red to terminal 17 Connect the ve lead black to terminal 16 Use suitably rated connectors between the fuel pump flying lead and any external wiring Provides PWM variable output for correct pump speed Use quality water and dust resistant connectors for any inline joints Primary Coolant Pump Connect the primary pump ve wire to terminal 19 Connect the primary pump ve wire to terminal 18 31 Connect the electrical power and control wiring Install the WhisperGen Battery Connect the ve lead last Bank To prevent accidental electrical shorts connect the ve battery bank cable lead after completing all other equipment connections Connect the battery bank ve terminal via a 150 A circuit breaker and isolating switch to the ve terminal Connect the battery bank ve terminal on the WhisperGen side of the current shunt terminal When the battery bank cables are connected to the electronics box make sure that they are secured by the clamp and have not been inserted under the clamp by mistake The insulation on the battery bank cable should be cut back 25 mm Make sure the cables are
33. heating A microcomputer controls all the WhisperGen functions and displays real time operating conditions on an LCD control panel The WhisperGen DC output goes to a battery bank which provides an electrical buffer for the varying loads required When the battery bank charge is low the WhisperGen can be set to automatically start and bring the charge back up to a preset level Once the battery bank is charged the WhisperGen can be set to either stop or to continue operating to provide heat energy DC electrical items can be run directly off the battery bank and AC appliances via a DC AC inverter Purpose of this manual This manual details the correct installation procedure for the WhisperGen PPS16 12MD diesel fired generator with 12 V DC output WhisperGen PPS16 24MD diesel fired generator with 24 V DC output and their associated systems into recreational craft The WhisperGen must not be used in any other capacity Use the nstallation checklist on page 41 to guide you through installation A separate User Manual is provided for the general operation and maintenance of the WhisperGen Importance of correct installation Introduction and safety information Importance of correct installation The WhisperGen is technically advanced equipment that must be installed correctly for reliable operation It is recommended that installation be undertaken by a suitably qualified person This manual outlines the correct
34. his manual without necessarily notifying its users Variations in installation and operating conditions may affect the WhisperGen s performance Whisper Tech has no control over each installation s unique operating environment Hence Whisper Tech makes no representations or warranties concerning the performance of the WhisperGen under the actual operating conditions prevailing at the installation All operating parameters for each application should be validated by a technical expert of the user s choosing Whisper Tech has made every effort to explain all installation commissioning operating maintenance troubleshooting procedures warnings and safety precautions as clearly and completely as possible However due to the range of operating environments it is not possible to anticipate every issue that may arise Therefore Whisper Tech is not able to guarantee that this manual will address every issue that may arise This manual is intended to provide general guidance For specific guidance and technical support contact your authorised WhisperGen supplier Information in this manual shall not be deemed a warranty representation or guarantee For warranty provisions applicable to your WhisperGen please refer to the warranty provided by the supplier of your WhisperGen Unless otherwise noted reference to brand names product names or trademarks constitute the intellectual property of the owner thereof Subject to your right to
35. ion ie ER Led eee oben ice tete Det od vea oe 38 WhisperGen DC Marine Installation checklist nene 41 Introduction and safety information Overview of the WhisperGen Introduction and safety information Overview of the WhisperGen Key WhisperGen Battery bank DC AC inverter Standard domestic appliances Hot water for domestic use Space heating Excess heat removal 12 or 24 V equipment Cool exhaust vent OND Ue O N The WhisperGen is a combined heat and power generating system providing efficient low maintenance generation of DC electric power The WhisperGen uses a four cylinder double acting external combustion Stirling cycle engine Interconnected cylinders are pressurised with nitrogen gas and sealed The gas is heated at the top of the cylinders by a continuous combustion burner and cooled at the bottom by coolant circulation The resulting change in pressure causes pistons inside the cylinders to move up and down A unique wobble yoke mechanism ensures the correct phasing of the pistons and converts their linear motion to rotary motion to drive a DC electrical generator which can be used to charge a battery bank The heat generated by the burner is removed by coolant circulating through the engine cavities The coolant used in the WhisperGen is circulated by pump to heat hot water cylinders and to provide cabin
36. l system Coolant system Engine Generator electrical output IP rating Thermal Electrical Exhaust temperature Exhaust emissions Condensate Type Consumption at nominal output Microprocessor User interface Flow rate nominal Type 38 4 cylinder double acting Stirling cycle with single point modulating continuous burner 12 V DC or 24 V DC IP44 5 5 kW at 100 burner rate 12V DC 70A 24V DC 35A 90 C nom 150 C max in extreme fault conditions O content 8 9 CO content max 200 ppm max 1 0 L h Automotive diesel BS2869 1998 burner fuel class C2 0 75 L h 2 microprocessor control Remote LCD control panel 6 to 10 L min Recirculated coolant Appendices Technical specification Dimensions Connections Compliance Max system pressure Max normal temp Max fault temp Length x depth x height Dry weight dry Fuel Coolant Condensate drain Exhaust Battery bank cable Aux equipment Comms port Maximum 100 kPa 70 C 84 C 390 x 500 x 650 mm 90 kg 1 8 BSP ISO 7 1 3 4 BSP ISO 228 1 1 2 OD stub 1 1 4 BSPP Female stainless steel 50mm screw terminal 0 5 to 2 5mm screw terminals RJ 45 via RS485 RS232 converter The WhisperGen complies with the following four European Commission Directives Machinery Directive 98 37 EC Electro Magnetic Compatibility Directive 2004 108 EC Waste Packaging Directive 94 62 EC
37. lant 1 Bleed OFF Check the complete system for leaks and if possible pressure test the primary coolant system to a maximum of 100 kPa 35 Bleed the secondary cooling system Prepare for commissioning Bleed the secondary cooling system Overview Bleeding the secondary coolant system requires the opening and checking of the seacocks operation of the secondary coolant pump from the control panel and visual confirmation of the required flow from the outlet Procedure To bleed the secondary cooling system 1 Make sure the secondary cooling system hoses and connections are secure Open the inlet and outlet seacocks Check for leaks From the default display on the Control panel press Right Arrow to access the menus User Menu 5 Press Down Arrow to scroll down to the Installation Menu Installation Menu Press Right Arrow to access the Installation Menu 7 Press Down Arrow to Coolant 2 Bleed Coolant 2 Bleed 8 Press Right Arrow to edit the setting Press Up Arrow to turn Coolant 2 Bleed ON The primary coolant pump will also operate when you are bleeding the secondary cooling system Coolant 2 Bleed ON After 5 minutes of user inactivity the control panel reverts to the default screen If you need to go back to the default screen before this press Left Arrow until it is displayed 9 Check the outlet for flow The flow rate should be 6 10 L min If the flow cannot be observed due to the position
38. long with any warnings instructions and procedures in this manual the user should also observe any such other common sense procedures generally applicable to equipment of this type Failure by the user to comply with any warnings instructions procedures or any such other common sense procedures may result in injury equipment damage property damage or poor performance of the WhisperGen The major hazards involved with operating the WhisperGen include explosion fire z carbon monoxide fumes and electrical shock These hazards can be avoided if the user adheres to the procedures in this manual and exercises all due care Whisper Tech accepts no liability for direct indirect incidental special or consequential damages resulting s from failure by the user installer or service technician to follow any warnings instructions and procedures in this manual or any such other common sense procedures generally applicable to equipment of this type The foregoing limitation extends to damages to person or property caused by the WhisperGen or damages resulting from the inability to use the WhisperGen including loss of profits loss of products loss of power supply the cost of arranging an alternative power supply and loss of time whether incurred by the user its employees the installer a service technician or any third party Whisper Tech reserves the right to change the specifications of its products or the information in t
39. ng plant The wooden pallet is Pinus radiata and has been heat treated to ISPM15 phytosanitary standards It can be recycled or incinerated Remove and re fit the enclosure Remove the enclosure Remove the rubber straps from the retaining hooks and lift off the enclosure Enclosure cover showing retaining hook Refit the enclosure To refit the enclosure Make sure the enclosure is correctly seated on the rubber seal and that no wiring or pipelines are trapped Refit the rubber straps 25 Lift the WhisperGen Install the WhisperGen Lift the WhisperGen Lifting procedures and equipment must comply with all local laws and regulations Always use suitable mechanical lifting gear when moving the WhisperGen The WhisperGen dry weight is 90 kg To lift the WhisperGen with the engine enclosure ON place slings under the engine enclosure To lift the WhisperGen with the engine enclosure OFF secure the lifting slings to the two lifting lugs on the front right and back left of the engine Lift the assembly carefully making sure that no wiring or pipelines are caught in the lifting equipment When the WhisperGen is at floor level use a mechanical aid such as a trolley for moving it Attach the exhaust heat exchanger Burner The exhaust heat exchanger is detached from the burner and supported by a transit bracket on the back of the enclosure during shipping To attach the exhaust heat exchanger to the burner manif
40. nger 8 Diesel water heater 9 Radiators air water heater 10 Expansion or header tank 11 Pump if not fitted to heater 12 Thermostat 14 Design and plan your installation Primary cooling system boat heating system Component specifications The components listed apply to Options 1 amp 2 above Most components are available in the optional installation kits on page 7 Header tank Coolant pump 12 V DC for 12 V models 24 V DC for 24 V models Max power 50 W Max system pressure 100 kPa 20 30 L min capability Min system flow rate of 6 11 L min Hose pipe fittings do not use brass or copper 3 4 BSPT male x 3 4 hose or pipe fittings x 2 Nylon or stainless steel rated for continuous operation at 125 C 200 kPa Flexible hose or pipework Domestic hot water central heating system type pipe or reinforced flexible hose Rated for continuous operation at 125 C 200 kPa min 19 mm ID Hose pipe clips Marine grade stainless steel Header tank sealed with pressure cap Rated for continuous operation at 125 C 200 kPa min Volume to be at least 5 of the volume of liquid in the circuit Minimum 3 litre operating capacity Coolant Clean distilled water and high quality marine grade corrosion inhibitor suitable for use with aluminium and any other metals that may be encountered in the system i e steel copper If freezing conditions are expec
41. old Remove and discard the wooden block from the face of the burner manifold Carefully lift the exhaust heat exchanger off the enclosure and position the four mounting studs through the holes in the face of the burner manifold Bolt the exhaust heat exchanger to the burner manifold using the 4 x M5 nuts and washers supplied and torque to 5 Nm The transit bracket can be left in its original position bolted to the top of the heat exchanger Alternatively it can be removed but must be available in case there is a future need to transport the WhisperGen Exhaust heat Wooden block exchanger 26 Install the WhisperGen Fix the WhisperGen into position Fix the WhisperGen into position Mount the WhisperGen into position using the WhisperGen fixing template supplied with the WhisperGen and the information and fixing point dimensions in the illustrations below The WhisperGen can be mounted from the top or from underneath Ensure that all plumbing services are correctly positioned for easy connection to the WhisperGen before fixing it into position 450 0 I oO Q D E If fixing from underneath use 4 x M10 f fixing from the top use 4 x M8 bolts allowing sufficient length to bolts allowing sufficient length to pass through the floor plus 25 mm pass through the floor plus 60 mm for screwing into the WhisperGen for passing through the WhisperGen fixing point fixing point 22 Nm torque 9 Nm
42. onal installation kit Selecting a site for the WhisperGen Designing and installing the fuel cooling exhaust condensate drain freshwater flushing and battery systems Please read all the guidelines and prepare a detailed design and installation plan before commencing any installation work Equipment supplied with the WhisperGen The following equipment is supplied with every WhisperGen 1 BP eo DN ee COL 9 WhisperGen Model PPS16 either 12 V or 24 V Control panel and mounting clamp either 12 V or 24 V Control panel cable 10 metres Fuel pump 12V Mikuni ESP12 MY11A or 24V Mikuni ESP12 MY12A Current shunt 500 A 50 m V Battery bank temperature sensor Fuse and inline holder 2 A Spare fuses Blade type 3 5 10 15A Cartridge type 32A Installation Manual and Checklist 10 WhisperGen fixing template 11 User Manual Design and plan your installation Installation kits optional Installation kits optional The optional installation kits contain hoses hose fittings pumps valves electrical components and other parts compatible with the WhisperGen that will be required in all new installations and in some retro fit installations Contact your WhisperGen agent for current details of the kit relevant to your installation The part numbers are Heating option Potable water heating and up to 5 5 kW space heating short heating circuit and or new installation
43. r the battery bank The connections are sound and the polarity is correct The conductor sizing is correct The battery bank and WhisperGen are installed as close together as practical The total cable length between the WhisperGen and the battery bank is kept below 8 m if longer distances are required cable diameter must be increased Longer cable lengths result in high voltage drop and poor charging performance 24 Install the WhisperGen Unpack the WhisperGen Install the WhisperGen Unpack the WhisperGen The WhisperGen is shipped bolted to a pallet and covered with all liquids drained To unpack the WhisperGen 1 2 Remove the straps and carefully lift the packing box clear Unbolt the WhisperGen from the pallet and lift off See Lift the WhisperGen on page 26 Lift off the enclosure See Remove and re fit the enclosure on page 25 Remove the control panel fuel pump and current shunt from inside the WhisperGen enclosure Inspect the parts for dents scratches water damage corrosion and any other shipping damage If any part of the WhisperGen is damaged or missing please contact your WhisperGen representative Dispose of the packaging Contact your local recycling centre for advice on recycling the WhisperGen packaging Consider the following The cardboard packing box is paraffin wax coated and should be incinerated The cardboard infill packing is recyclable at a paperboard recycli
44. s with a Teflon tape or Locktite 577 system Sealall brass type connections with Locktite 577 Sealall stainless steel type connections with a suitable anti seize compound After the fuel and exhaust connections have been made ensure there are no fluid or gas leaks by carrying out an appropriate pressurised leak testing procedure Do not exceed the specified maximum system pressures 28 Install the WhisperGen Install the control panel Install the control panel Positioning Installation procedures Warnings amp cautions Select a site for the control panel which is dry and allows free access for the communications cable You must have access to the rear of the wall that the control panel will be installed in A 10 m communications cable is supplied with WhisperGen Ensure the control panel is sited within reach of the cable To install the control panel 1 Cuta 127 mm x 111 mm hole in the wall that the control panel will be installed in 2 Feedthe control panel cable from the WhisperGen to the hole in the wall 3 Run the control cable from the WhisperGen to the control panel The control cable is supplied coiled inside the WhisperGen enclosure Open the enclosure See Remove and re fit the enclosure on page 25 and feed the cable through the cable gland in the rear panel of the WhisperGen 4 Plug the cable into the port at the rear of the control panel and fit the control panel into th
45. ssure relief valve certified 100kPa 12 Corrosion inhibitor added 12 System bled 34 Installer declaration hereby certify that the WhisperGen has been installed in accordance with the installation manual and accept liability for the cost of travel and time of the commissioning agent in the event that incomplete or incorrect installation results in the agent incurring time and cost over and above that required for commissioning of a correctly installed WhisperGen Signed Date 41 www whispergen com
46. ted a glycol based marine grade anti freeze is to be used All additives must be pre mixed Do not connect the boat s main engine cooling system to the same circuit as the WhisperGen as cast iron contaminants may damage the WhisperGen If the coolant system is used to heat the vessel potable water system a compatible non toxic corrosion inhibitor and anti freeze if required must be used Relief valve and discharge pipe Certified 100 kPa relief valve Discharge pipe that is no less a bore than the bore of the connection to the valve Hot water cylinder calorifier Min capacity 40 litres Coil length 1 0 m per 20 L capacity up to a maximum of 10 m min 13 mm ID In a typical installation a header tank must be installed at the highest point in the primary coolant system directly upstream of the circulation pump The header tank provides a point for filling and bleeding the system and allows space for thermal expansion If use of a header tank is not possible use a pressurised accumulator system 15 Primary cooling system boat heating system Design and plan your installation Relief valve The pressure relief valve must be fitted directly to the WhisperGen primary coolant outlet connection Make sure there is no intervening valve or restriction between the outlet connection and the relief valve The discharge pipe must be fitted and located so that The discharge of water or steam from the valve is visibl
47. tion e ib et OR ERU gt USUS C REUS Eb ete a 5 Design and plan your installation 1 eeeeeee sees esee eene nennen nennen nnne nnns annt nnns inna sane nn nda s tena suse nenas aset nnna nanana 6 Introduction DE ES 6 Equipment supplied with the WhisperGen ssssesssesseeeeeeeeeeeennneen nennen nennen neret enne nnn rennen nennen 6 Installatiori kits Optlorial 4 5 cre certe t Dice ettet ei me vente vise nee re biete esate ued esee Eee 7 Selectia site for the Whisper eli 5 5 2 eee DR GNI ep rtt OR HIR en Ed nte eee erint 8 la Ku MM P 9 Primary cooling system boat heating system ssssssesseseeeeeeneeeem eene nere nere 12 Secondary cooling system seawater heat dump circuit seesssssseseeeeeneeeenen nene 18 ExhauSt amp condensate Qrallt i emet do Poste tert eite teet eb aa ie c tpe Ceo smue cU ee A Deed 21 Fresh water fl shlng ioi e RR COBRAR SENA n dee OUR BER E T 23 Battery bank M c edi iin ae eae en an an ey eee 24 Install the WhisperGen 5er iere en Dni cee tbe AS ede cacti seek oc reek ie ui ceo ee dceeteere seceded 25 Unpack the WhisperGe ms sits o ER esci eet e a diese aay ERE ER d E esa ROB aie 25 Dispose Of th packagling oH RERO IRR OR ER RR cesesaceaadateeess 25 Remove and re fit the enclosure c s ecessec
48. to access the Installation Menu 8 Press Down Arrow to Fuel Bleed Fuel Bleed 9 Bleed the system until it is clear of air Allow the system to bleed for at least 10 minutes Fuel Bleed ON 10 Turn Fuel Bleed to OFF To do this From the default screen on the control panel press Right Arrow to access the menus Press Down Arrow to get to the Installation Menu Press Right Arrow to access the Installation menu and press Down Arrow to Fuel Bleed Press Right Arrow to edit the setting and press Down Arrow to turn Fuel Bleed OFF 11 Reconnect the fuel line to the evaporator 37 Transporting by land or air Appendices Appendices Transporting by land or air Before transporting the WhisperGen unbolt the exhaust heat exchanger from the burner and use the bracket supplied See Attach the exhaust heat exchanger on page 26 to attach it to the rear of the enclosure When transporting ensure that Suitable packaging is placed around the WhisperGen engine to prevent any movement The WhisperGen is on a pallet All fluids are drained and fittings plugged The WhisperGen is upright and secure All covers are fitted and the WhisperGen is protected from the elements The WhisperGen is clearly labelled as dangerous goods 24 bar pressurised nitrogen for freight purposes All airline requirements are complied with Technical specification General Outputs Fuel Contro
49. tribution board Measures the battery bank charge and discharge to provide amp hr value Connect the current shunt in series between the WhisperGen ve terminal and the battery bank ve terminal Ensure all external loads are taken from the WhisperGen side of the current shunt Do not connect any external loads or other generation sources between the current shunt and the battery bank This will result in a false Amp hr value and poor battery bank charging Battery Bank Voltage Sensor 120r24V Measures the battery bank voltage Connect the battery bank ve terminal to terminal 9 Install an inline 2A fuse in this line The fuse is supplied with the WhisperGen Connect the battery bank ve terminal to terminal 10 The battery bank ve terminal will remain live even when the WhisperGen is isolated from the battery bank To fully isolate the WhisperGen remove the 2 Amp fuse Battery Temperature Sensor Measures the battery bank temperature to control the rate of charging to avoid overheating the battery bank Connect the battery bank temperature sensor to the battery bank ve terminal and connect the blue lead to terminal 11 Secondary Coolant Pump 120r24V Connect the secondary sea water pump ve to terminal 13 Connect the secondary sea water pump ve to terminal 12 These outputs are PWM and provide variable speed pump control The secondary pump will only start when required Ensure the pump is t
50. ver the cylinder and that sufficient water volume is available Install a by pass circuit in the cabin heating heating system This will ensure that water flow is maintained Flow rate min max This is the flow rate 6 11 L min requirement for the complete installed system Pressure drop across the WhisperGen at 20 C 40 kPa at 11 L min temperature difference Operational specifications temperature difference Max electrical load 16 Design and plan your installation Primary cooling system boat heating system Warnings and cautions If the coolant system is connected to the vessel potable water system a compatible non toxic corrosion inhibitor must be used Do not connect the boat s main engine cooling system to the same circuit as the WhisperGen as cast iron contaminants may damage the WhisperGen Use only the specified coolant Use of incorrect coolant will result in corrosion of the WhisperGen and will void the warranty Always refer to manufacturer s instructions for corrosion inhibitors and anti freeze solutions 17 Secondary cooling system seawater heat dump circuit Design and plan your installation Secondary cooling system seawater heat dump circuit Overview of the entire coolant system Key Exhaust heat exchanger Core engine Clamp element heater Generator housing Marine heat exchanger Secondary cooling in Secondary cooling out Primary coolant in Primary coolant out Oo N
51. view of fresh water flushing system Component specifications Isolation valve Operational specifications Warnings and cautions The exhaust heat exchanger is flushed with fresh water for 10 seconds each time it is started and every 10 hours during operation to prevent soluble deposit build up from the fuel The fresh water is normally plumbed from the domestic pressurised fresh water supply to the fresh water connection on the back of the WhisperGen The flushed water drains into the condensate tank and exits the WhisperGen via the condensate drain Connection to back of WhisperGen 3 4 BSP female connection required WhisperGen has a 3 4 BSP male connection An isolation valve must be fitted between the supply and the WhisperGen The isolation valve must be left open when the WhisperGen is operating and closed in the case of emergency or servicing Discharge flow rate nominal 1 L hr Flow rate max instantaneous when 25 ml sec max 10 sec flushing Supply pressure 150 to 600 kPa 20 to 90 psi For the fresh water flushing avoid using hard water if possible The use of water with high calcium or magnesium concentrations can result in nozzle blockage which will mean regular cleaning 23 Battery bank Design and plan your installation Battery bank Overview of the battery bank Component specifications Installation The WhisperGen DC output goes to the battery bank via the current shunt ve
52. way to install the WhisperGen After the WhisperGen is installed an authorised WhisperGen representative must do the final system checks a first start and commissioning Failure to use an authorised WhisperGen representative for commissioning may result in the warranty being void Please keep this manual in a secure place near the WhisperGen Symbols in this manual Symbols are used in this manual to highlight information that is critical to the safety of people and equipment and to the safe and correct operation of the WhisperGen An extreme hazard which may result in death or injury if proper precautions are not taken A reminder of safety practices or unsafe practices which could result in personal injury or damage to associated equipment A reminder of safety practices or unsafe practices which could result in damage to the WhisperGen and or void the warranty Important information essential to the installation and operation of the WhisperGen Emergency procedures Stopping the WhisperGen Isolating the WhisperGen from the battery bank In the event of fire To stop the WhisperGen in an emergency Push and hold the Stop button on the controller until it beeps and or Use the emergency fuel isolation valve on the front panel of the WhisperGen to isolate the fuel supply to the burner and or Shut off the fuel isolation valve at the fuel tank outlet If fuel vapours are detected in close proximity to the
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