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Whisper Power W-SC6 Technical information

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2. Fe F3 10 Auxlary Dig Dies Control Int fuel pump S TO DDC REG t 5 Es I Nd a 5 3 3x PLUS TERMINALS 5 sis IS IS k 15161 l ls START STOP Local Operation Unit vo 10 MIN TERMINALS RED 9 Je4 COMPUTER CONNECTION BLACK 17 JI6 CABLE 2x1 5 mma CABLE 2x0 75 mma TERMINAL BLOCK CABLE 2x1 5 mm2 BROWN L1 YELLOW GREEN PE BLUE WHITE WHITE BROWN 33 gt up PROPORTIONAL ACTUATOR Fig 13 Diagram electronic governor EN M SC6 8 10 December 2010 19 6 whisper Power OPERATION P 3 OPERATION 3 1 GENERAL In operation checks The generating set is operational after full installation and 1 Check for abnormal noise or vibration filling up with fuel engine lubricating oil and cooling liquid Check the voltage filling the starter battery with acid connecting the battery Check sea water flow at exhaust outlet to earth and connecting the digital remote control panel Power source selector switch off shore power generator power Switch to power source generator If a Masterswitch is installed this operates automatically 5 Before loading the generati
3. aa 34 5 4 1 Setting the FR PM t 34 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts 35 5 4 3 Measuring exhaust ei 36 5 4 4 Disassembling 36 6 SPARE PARTS LIST 38 MAINTENANCE LOG 4 40 EN M SC6 8 10 December 2010 3 INTRODUCTION gt 1 INTRODUCTION 131 GENERAL The M SC6 8 10 Marine Diesel Generating set is manufactured and marketed by WhisperPower It is important to read this manual before installing and operating the generating set Both safety and durability rely very much on the correct identification installation and a good understanding of ratings features design maintenance and operation procedures The information specifications illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the WhisperPower M SC6 8 and 10 generating set This manual is valid for the following models Part Description number 41102005 M SC6 230V 3000rpm 41102006 M SC6 23
4. c 23 4 2 4 izle 23 4 2 5 Replacing OM MER e 23 4 2 6 Readjustment of the V belt niinniin Ss 24 4 3 DRE PERS 24 4 3 1 Maintenance schedul ns sense ee einen 25 4 3 2 Putting Out Of SENICE scan cmm 26 5 TROUBLE SHOOTING ESS 27 5 1 Alternator electrical BT c p rand 27 5 1 1 27 5 1 2 Trouble Shooting 27 5 2 29 5 2 1 Generals LEE 29 5 2 2 IieiEuenhaciuM 29 5 2 3 EIE 5 2 4 DEVICE ACCESS vee 5 3 Special procedures alternator 5 3 1 Residual voltage check excitation procedure een eene 33 5 3 2 Testing rotary rectifier dlodes rra o uera eu oed 33 5 3 3 Winding resistant values e 34 5 3 4 MSGgGSNAG zoeen mm 34 5 4 DPeClal procedures SNGING
5. iis 14 2 5 10 14 2 5 11 Oil information ii 14 2 5 12 Gooling liquid o tto 14 2 5 13 Technical data c 15 2 5 14 Wiring codes and colours enne e eren 16 2 5 15 Lay out control Wird E 17 2 5 16 Electrical diagram 230 V 50 2 44 0 000 18 2 6 GOVE Ino m 19 3 A ee E A A E 20 3 1 Generalized detenta 20 3 2 Operating IMStMUCHONS ees 20 3 2 1 Summarised operating instructions daily use eem 20 3 2 2 Extended operating 21 2 December 2010 M SC6 8 10 EN lt gt 5 4 cis ccd M 23 4 1 ACTIE Hu 23 4 2 Engine 23 4 2 1 Preliminary INStrUCtONS n 23 4 2 2 Bleeding fuel te 23 4 2 3
6. Low compression because of dirty valves Clean valves Take off the injection bent and inspect the outlet port When little rust in the port clean the valve by taking off the valve spring and rotate until rust is removed When the outlet port is strongly affected by rust the exhaust system is not properly installed refer to paragraph 5 4 3 Contact WhisperPower service department for advice e Blocked injector Have the injector tested and cleaned if necessary e Loss of compression by wear out or Repair by WhisperPower service damage Engine runs irregularly e Unsuitable contaminated fuel e Lack of fuel Fill up with fuel or replace by better quality e Choked fuel filter Check fuel filter and fuel lift pump clean or replace if necessary e Faulty fuel lift pump Check and repair e Choked air filter e Lack of air Check the air intake e Choked exhaust system exhaust blocked rubber exhaust hose kinked Check the exhaust hose e Air in the fuel pipes e Faulty electronic governor only if applied Bleed air from fuel system refer to maintenance section Replace faulty parts e Blocked injector Have the injector tested and cleaned if necessary e Wrong valve clearance Adjust valve clearance e Temporarily hunting this will disappear when engine has run in e Ongoing hunting caused by faulty electronic governor only if applied Repla
7. 0020 JULY USERS MANUAL M SC6 8 10 3000 RPM Marine diesel generating set 230V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 December 2010 CONTENTS GL CONTENTS 1 INTRODUCTION saati 4 1 1 Chr 4 1 2 Senice and MAINLCMANCE IDEEN 4 1 3 GS WA AIMS 4 1 4 Erb E 5 1 5 Deme 6 1 5 1 Cac 6 1 5 2 Identification se 6 2 INFORMATION c 7 2 1 STIN ees 7 2 1 1 GONG C Un 7 2 1 2 Electrical safety sor re 7 2 1 3 Earth insulation Teall 06S abri iter oeque a nr ate as 7 2 1 4 EE og ere 7 2 1 5 en p 8
8. e Starter battery switched OFF Check position of the battery switch and switch ON e Starter battery voltage insufficient battery too weak Check battery voltage Recharge the battery Inspect battery terminals and cables for a good electrical connection inspect against corrosion tattered wires etc e Faulty fuse Replace fuse e Wing control system faulty During the normal starting process the battery voltage drops to 11V with a fully charged battery If the voltage does not drop during starting the electrical connection is faulty If the battery voltage drops lower than 11V then the battery has been discharged too deep e Starter broken Repair the starter motor EN M SC6 8 10 December 2010 29 TROUBLE SHOOTING PROBLEM CAUSE SOLUTION e To thick engine lubricating oil Change oil for a lower viscosity Starter is turning engine smoothly but engine fails to start e Out of fuel or faulty fuel water in the fuel Fill up with fuel or replace with better quality e Fuel solenoid is not opening Check wire connections and circuitry to solenoid Refer to DC wiring diagram e Fuel lift pump is not working Fuel filter is blocked e Air in fuel lines Check fuel filter and fuel lift pump clean or replace if necessary Bleed air from fuel system refer to maintenance section e Wrong valve clearance Adjust valve clearance
9. Check and tighten nuts bolts and unions paying particular attention to the fuel system Observe the exhaust at the normal full load The exhaust must be free from soot Do not allow the engine to run with a dirty exhaust without investigating the cause as this may result in an expensive breakdown Check air vent on a regular basis When the air vent it not working properly the engine can fill up with water by siphoning Water in the combustion chamber causes serious damage to the engine Check and readjust V belt Check the electrical connections EVERY 150 HOURS Change oil Check the battery acid level not applicable when WhisperPower batteries are used Check battery terminals for corrosion Check and readjust V belt Check impeller raw water pump durability depends on the purity of the sea water In sandy water and warm water wear will increase 24 December 2010 M SC6 8 10 EN ED MAINTENANCE When replacing the impeller the gasket between the pump case and the cover should be replaced as well So when ordering a spare impeller order a gasket as well Remove the cover to get access to the impeller Remove the old impeller with the help of two screwdrivers Install the new impeller and add some grease Turn the blades in the direction of rotation of the pump i e anti clockwise looking at the impeller EVERY 300 HOURS Replace the impeller of the raw water pump e Retighten cylinder head bolts a
10. December 2010 A restart protection prevents starting the engine when it is already running which could cause damage In the event of starting problems numerous A attempts are made close the sea water inlet cock while cranking to prevent the outlet system and engine to fill up with water During the starting process the cooling water pump is driven with the engine The cooling water is discharged to the exhaust outlet because the engine does not run the exhaust pressure is not high enough to expel this water Open the valve directly when the engine starts to prevent damaging the impeller Water in the cylinder will cause serious damage to the engine For instance a bent piston rod or a cracked cylinder head In fact water in the cylinder is the main cause for engine damage in pleasure craft Checks once the generator is in operation 1 Check for abnormal noise or vibration 2 Check the voltage 3 Check coolant flow Always check immediately after starting the generator if cooling water flows at the exhaust outlet If this is not the case check the cooling water pump After having become acquainted with the generator you will be able to recognise the coolant flowing through the system by listening for the noise of the water which is expelled Be aware that especially in harbours the A coolant water inlet can easily be blocked by floating objects 4 Power source selector switch off shore power generator power Swi
11. Example 2 Misuse Long term running with no load or too little load can cause the exhaust to get choked with soot or carbon Cleaning the exhaust is not covered by warrantee Example 3 Neglect Sometimes the seal of the raw water pump starts leaking Mostly this begins with a little drip and slowly gets worse Regular visual inspection of the generator is necessary to prevent damage to occur from a leaking water pump When one find serious damage after weeks of neglect warrantee claims will not be honoured Example 4 Neglect Whisper generators have an option for an auto start stop mode or interval mode WhisperPower cannot be held responsible for damage caused by the unattended running generator Guarantee means that faulty parts are repaired or replaced free of charge If necessary the whole generator unit will be exchanged Labour necessary to complete repairs on board a vessel executed by an authorized service engineer is covered but is limited to a reasonable number of hours and reasonable rates in relation to the actual repair work that has to be done Travel expenses and travel hours are not covered Also not covered is the labour required to take a generator out of a boat or for reinstallation There is no cover for labour needed to get access to the generator for example to remove equipment or bulkheads etc Goods to be delivered under warrantee will be invoiced Only after the faulty goods are returned will the invoice
12. 2 1 6 dicz ui0ESdDLImeeL E EM 8 2 1 7 GIG MICAS zen ene ee ee ee ees 8 2 2 Transport lifting and storage o 9 2 3 566 8 10 9 2 3 1 Features 9 2 3 2 Remote COMMON a 9 2 3 3 Peel 9 2 3 4 Accessories included in the standard delivery eene 9 24 5 10 2 4 1 Main components to identify ceci iiie eset vanne innate Dade dne kann Eau dne 10 2 4 2 Generator controlpanel E 13 2 4 3 Remote controlpanel E UE 13 2 5 Technical luii e 13 2 5 1 De pruarmM H M 13 2 5 2 Engine 13 2 5 3 Digital Diesel Control 13 2 5 4 Battery Charger I 14 2 5 5 Alarms ANG SHUL GOWN itessicncesesenenie tats 14 2 5 6 ey 14 2 5 7 Disce pte Em 14 2 5 8 Hour counten rr 14 2 5 9 Load
13. A failure code is displayed when a hardware failure at the generator is detected COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage EXHAUST TEMP Exhaust temperature is too high WATER TEMP Coolant temperature is too high OIL PRESSURE Oil pressure failure AC VOLTAGE Generator AC output voltage is either too high or too low HIGH CURRENT Generator is in overload FREQUENCY Output frequency of the generator is too low 5 2 2 Trouble shooting table PROBLEM CAUSE SOLUTION Diesel engine fails to crank the Almost certainly this is an electrical Check on water in the cylinder and further starter makes clicking noises or the engine cranks very slowly START BAT problem Display will indicate LOW damage by cranking When there is water in the cylinder then deactivate the control One other possibility is that the engine system disconnect the battery remove the is locked by water the cylinder or glow plugs Crank the engine to remove the there is other severe damage water through the opening of the glow plugs Check oil on the presence of water and change oil Find out how the water did enter the cylinder check the air vent Take precautions to prevent it from happening again When there is no mechanical malfunction the problem must be an electric malfunction
14. Battery negative Battery positive Fuel out 8mm Raw water inlet V belt Engine coolant pump Exhaust manifold watercooled Temperature switch Thermostat housing Filler cap engine oil Filler cap engine coolant Rocker cover Hoist eye rear Expansion tank Bypass cooling water out Bypass cooling water in Generator Exhaust hose 40mm AC power output Remote control Engine air intake 11 INFORMATION GI 25 Cooling water injection bend 26 Temperature switch exhaust 27 Heat exchanger 28 Starter motor solenoid 29 Starter motor 30 Rubber engine mounting 31 Fuel in 8mm 32 Battery negative 33 Battery positive 34 Fuel out 8mm 35 Raw water inlet 36 V belt 37 Engine coolant pump 38 Exhaust manifold water cooled 40 Temperature switch 41 Thermostat housing 42 Filler cap engine oil 43 Filler cap engine coolant 44 Rocker cover 45 Hoist eye rear 46 Expansion tank 47 Bypass cooling water out 48 Bypass cooling water in 49 Generator 50 Exhaust hose 40mm 51 AC power output 52 Remote control 53 Engine air intake Fig 7 Rear view main components M SC10 12 December 2010 M SC6 8 10 EN ED
15. E EN Po ud Cc I3NVd 1 ALN 19901 EE INE EE NADIE 1 1 OV sOLVaaN39 DL 1 2 Fig 11 Lay out control wiring 17 EN M SC6 8 10 December 2010 INFORMATION 2 5 16 Electrical diagram 230 V 50 Hz STATOR GREEN 1 EXCITATION WINDING GREEN 2 CAPACITOR EARTH AND NEUTRAL NOT CONNECTED RED 3 230V 50Hz BLACK 11 RED 11 MAIN WINDING YELLOW GREEN PE MAIN WINDING BLACK 4 YELLOW GREEN CURRENT TRANSFORMER E 230V 50Hz BROWN 11 YELLOWGREEN EARTH AND NEUTRAL CONNECTED Fig 12 Electrical diagram 230V YELLOWIGREEN 18 December 2010 M SC6 8 10 EN ED INFORMATION 2 6 DIAGRAM ELECTRONIC GOVERNOR The M SC8 and 10 3000 rpm are equipped with an electronic governor in addition to the mechanical governor that is on other Whisper models 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 has only a mechanical governor can drop 75 RPM 72 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 v
16. Masterswitch is installed this is done automatically If the engine is not running and failure and A charging LED is blinking reset by stop button otherwise it will drain the start battery 22 December 2010 M SC6 8 10 EN gt MAINTENANCE 4 MAINTENANCE 41 ALTERNATOR The alternator does not require any maintenance Periodic inspection and cleaning is recommended depending on environmental conditions However when the alternator has been idle for a long period attention to winding condition is recommended The condition of windings can be assessed by measurement of insulation resistance to earth The CAPACITOR should be disconnected during this test A 500V megger or similar instrument should be used The insulation resistance to earth of all windings should be in excess of 1 0 MOhm Should the insulation resistance be less than this value drying out the generator windings is essential Drying out can be carried out by direct warm air from a fan heater or similar apparatus into the generator air inlets or outlets All bearings are greased for life and not regreasable 4 2 ENGINE 4 2 1 Preliminary instructions All regular maintenance can be carried out when the enclosure is open When oil and dirt has gathered in the enclosure measures have to be taken to avoid spilling oil and polluting the environment The first service on the engine should be carried out after 50 hours of its life and afte
17. SC6 8 10 December 2010 2 3 THE M SC6 8 10 2 3 1 Features This generating set includes a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s left side The set is not self contained and is only operable after proper installation using additional accessories and installation materials Installation accessories are listed in the installation manual and are available through the supplier of the genera ting set The full automatic Digital Control is based on microprocessor technology Several automatic start stop functions can be programmed and monitored refer to Digital Diesel Control user manual 2 3 2 Remote control The full automatic remote control panel including 15 mtr cable comes as standard with the M SC6 8 10 2 3 8 Documentation Included in the delivery are e This user manual number 40200351 An installation manual number 40200361 e A user manual for DCC number 40200261 e quick reference guide for DDC number 40200275 Not included in the standard delivery but available as options are e Parts manual number 40200381 M SC6 8 e Parts manual number 40200382 M SC10 e Workshop manual number 40200171 M SC6 8 10 However in this manual there is a list of important parts for maintenance and
18. T D C of compression stroke 2 The T D C of compression stroke can be found by aligning the T D C mark notch on the crankshaft pulley with the mark on the gear case ref to fig 24 Fig 24a 2 cylinder engine Fig 24b 3 cylinder engine 3 First align the T D C mark for the No 1 cylinder Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation If the rocker arms move piston no 1 is on the T D C of the intake or exhaust stroke In such case turn the crankshaft 360 EN M SC6 8 10 December 2010 in the direction of engine rotation again No 1 piston is now at T D C of the compression stroke 4 To adjust the valve clearance of the No 2 and No 3 cylinder a Two cylinder engine M SC6 and 8 the crankshaft pulley has to be turned 180 degrees clockwise to set this piston to T D C Adjustment can be executed b Three cylinder engine M SC10 After adjusting the valves of cylinder 1 turn the crankshaft 240 degrees clockwise from the T D C of cylinder 1 to the T D C of cylinder 3 Position 2 fig 24b against the notch Adjust the valves of cylinder 3 Then turn the crankshaft 240 degrees further clockwise to the T D C of cylinder 2 and adjust the valves position 3 fig 24b against the notch Check after each adjustment that the valves do not move up and down when turning the crank craft about 20 degrees clockwise and counter c
19. attempt to operate the generating set with a known unsafe condition Disconnect the battery positive lead prior to attempting any repairs or cleaning inside the enclosure e Always consult the manual before carrying out maintenance Donot change the settings without consulting the manufacturer Keep a record of setting changes in this manual 2 1 6 Fire and explosion Fuels can be flammable Proper handling limits the risk of fire and explosion 2 1 7 Avoid refilling the fuel tank while the engine is running When oil or fuel is leaking do not use the generating set Do not run the engine close to explosives or gasses Hydrogen gas generated by charging batteries is explosive Ensure for proper ventilation Do not smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand Poor electrical connections or using wiring which is not suited for the rated currents can cause overheating and possibly fire Chemicals Fuels oils coolants and battery electrolyte can be hazardous to personnel if not treated properly Do not swallow or have skin contact with these liquids Do not wear clothing that has been contaminated by fuel or lubricating oil Gaskets may be manufactured from asbestos Particles of this material should not be inhaled as this may result in fatal diseases On no account allow any unprotected skin to come into contact with the injector spray as
20. be credited Payment in advance may be required or guaranteed by credit card If after the faulty goods are returned it is indicated that the failure was not covered by guarantee a credit will not be issued For example if a EN M SC6 8 10 December 2010 Printed Circuit Board is returned with clear damage caused by seawater guarantee will be refused Freight costs to deliver spares by normal mail or carriers is covered under guarantee Special services like express mail overnight delivery etc are not covered Taxes and duties are not covered For shipments to remote off shore areas any additional costs incurred over normal carriage will be invoiced to the customer The cost for returning faulty goods is not covered under guarantee If any problem arises which could be subject of guarantee procedures should be followed as described in the guarantee certificate unauthorised repairs could lead to further damage and violate the guarantee conditions Should work take place which is not in A accordance with the guidelines instructions and specifications contained in this user s manual and the supplementary installation manual then damage may occur and the generating set may not fulfil its specifications In all these cases the guarantee may become invalid Use original spareparts only 1 4 LIABILITY WhisperPower does not accept responsibility for damage injuries or casualties which are the result of operation of the gene
21. factory at nominal 3000 50 Hz RPM A RPM drop of 5 6 at full load is acceptable Therefore a no load setting should be at 3150 RPM 52 5 Hz Under no circumstances should the RPM be under full load below 2940 RPM 49 Hz When no cause can be found for a wrong speed the setting can be adjusted Fig 22 2 adjustment screw RPM 3 manual stop It is very important to identify the correct setting assembly refer to fig 22 The screw is to be locked in position with the lock nut 34 December 2010 M SC6 8 10 EN ED TROUBLE SHOOTING 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts Both procedures have to be carried out with a cold engine When both procedures are carried out be sure to retighten the cylinder head bolts before adjusting the valve clearance When retightening the cylinder head bolts drain the coolant by removing the drain plug ref to fig 2 Loosen the bolts slightly remove the rocker assembly the rocker arms shaft and stays and then retighten the bolts to the specified torque in the numerical order illustrated ref to fig 23 Fig 23a Fig 23b M SC6 8 M SC10 M10 bolt 75 85 Nm M8 bolt 20 30 Nm M8 bolt 15 22 Nm Tightening torque Rocker stay tightening torque The clearance of both intake and exhaust valves should be 0 25 mm in cold condition 1 Set the piston of the first cylinder to be adjusted to top dead centre
22. the fuel may enter the blood stream with fatal results Engines may be fitted with seals or O rings manufactured from viton or similar material When exposed to abnormal high temperatures in excess of 400 C an extremely corrosive acid is produced which cannot be removed from the skin If signs of decomposition are evident or if in doubt always wear disposable heavy duty gloves December 2010 M SC6 8 10 EN ED INFORMATION 2 2 TRANSPORT LIFTING AND STORAGE When lifting the generating set avoid any risk of personal injuries do not stand un der the generating set Use soft slings to avoid damage e On the engine are two lifting eyes only to be used to take the generator out of the capsule Do not use to lift the set including the capsule and certainly not including the steel foundation plate e After transporting the generating set check for damage before installation e Long term storage can have detrimental effects on engine and alternator The engine should be put through an engine preservation procedure Refer to the maintenance chapter e alternator windings tend to condense To minimise condensation store the generating set in a dry and warm storage area After removing the generating set from long term storage perform an insulation check Refer to the alternator maintenance paragraph for procedures e While the battery is stored it should be recharged every 12 weeks EN M
23. user manual The microprocessor unit is located on top of the alternator 13 INFORMATION gt 2 5 4 Battery charger On the engine is an alternator generating 40 Amp 12V This current is rectified to charge the battery The voltage is regulated at 14 4V 2 5 5 Alarms and shut down In the event of malfunctioning this will be indicated by the failure light and details will be shown on the display the engine will be shut down There are three functions guarded oil pressure oil temperature and exhaust temperature Exhaust temperature too high indicates the cooling water to be blocked All alarm switches are closed when no malfunction occur A contact is cut in the event of an alarm This means that the generating set will not work when the alarm switches are broken or there is a loose wire The system therefore is intrinsically safe The panel will display details about the alarm 2 5 6 Control The generating set can be operated by push buttons on the panel on the alternator or by the remote control By pushing the START button the control system is activated and will start the engine automatically Pushing the STOP button will stop the engine and the electrical system will be deactivated 2 5 7 Remote control All wiring connections from the remote control to the board are made by plug in connectors An intermediate communication cable is in the standard supply If necessary an optional longer 8 wire cable can be con
24. 0V 3000rpm ungrounded 41103005 M SC8 230V 3000rpm 41103006 M SC8 230V 3000rpm ungrounded 41104005 M SC10 230V 3000rpm 41104006 5 10 230V 3000rpm ungrounded For other models see other manuals available on our website www whisperpower eu Our policy is one of continued development and we re serve the right to amend any technical information with out prior notice Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer distributor or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof 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 1 2 SERVICE AND MAINTENANCE Regular service and maintenance should be carried out according to the directions in this manual For service and maintenance one can appeal to the manufacturer or the dealers 1 3 GUARANTEE WhisperPower guarantees that this generating set has been built according to good workmanship according to the specifications
25. 2 5 mm2 battery gt ground black 25 mm2 ground gt LCP ground GND 2 black 2 5 mm2 DDC gt glow plug 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 oil temperature switch 7 blue 1 mm2 LCP gt oil 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 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 white 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 LCP 12 black 1 5 mm2 DDC LCP 14 red 1 5 mm2 DDC 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 16 December 2010 M SC6 8 10 EN INFORMATION 2 5 15 Lay out control wiring
26. E Generator AC output voltage is either too high or too low HIGH CURRENT Generator is in overload FREQUENCY Output frequency of the generator is too low 5 1 2 Trouble shooting table PROBLEM CAUSE SOLUTION No output Voltage at all Circuit breaker off or faulty fuse Check switches and fuses and measure directly on the alternator to exclude external causes e Low engine RPM Check the engine RPM and adjust refer to special procedures e Loss of residual magnetism Check the residual magnetism and flash the alternator refer to special procedures e Capacitor loose or broken Check by independent excitation if the problem is in the capacitor or in the windings e Rotor diodes broken Generator output voltage too No load at all or very low load Check the diodes in the rotor refer to special procedures The M SC6 8 10 has one diode in the rotor Switch on a load and check voltage low when no load is on it less e Engine is not reaching the rated RPM Refer to special procedures to readjust RPM EN M SC6 8 10 December 2010 27 TROUBLE SHOOTING PROBLEM CAUSE SOLUTION than 210V 105V e Defective capacitor Check capacitor and replace if necessary refer to special procedures e Defective diode one of the two Check the diodes in the rotor and replace refer to special procedures Generator output voltage too low under
27. INFORMATION 2 4 2 Generator control panel Sat Internal fuel pump Digital Diesel Control Fuse 3A Fuse 3A Remove fuse before maintenance Auxiliary External Fuel Pump ilg hee s Whisper Digital Diesel Operation Unit Cbserve instructions in the manual Replace fuses with same type and rating Fig 8 Control panel ad AC 1 gt Ac 2 2 EO Ofg fe Diesel Cor gt eat i start fuel fai A HH HAAA Fig 10 Digital Diesel Remote Control panel 2 4 3 Remote control panel Start button Stop button Select button Set button Failure lamp Generator load indicator Display NOOR EN M SC6 8 10 December 2010 2 5 TECHNICAL INFORMATION 251 alternator The single phase alternator is directly coupled one bearing brushless rotating field design two poles 3000 RPM and self regulating Residual magnetism causes a small voltage over the stator windings and allows a current to flow in the windings which is magnified because of the feedback effect between rotor and stator The field windings in the rotor are short circuited over a diode to rectify the current A capacitor over an additional winding in the stator which is at an angle with the power winding keeps the voltage stable within 5 96 at the specified
28. ROUBLE SHOOTING PROBLEM CAUSE SOLUTION e Wear out of cylinder Have the compression measured and have the engine overhauled Over temperature Overload Take away the overload e Low level of cooling oil or air in the cooling system Fill up with liquid and release air bubbles Check if there are air blocks in the system refer to the installation manual e Water inlet system blocked e Broken impeller e Water strainer choked e Heat exchanger choked Check the cooling system thoroughly e Broken or slipping V belt Replace and adjust the V belt tension e Faulty thermostat Check the thermostat or replace 5 2 3 Warnings A Generator must be shut off immediately if 5 2 4 Service address If you cannot correct a problem with the aid of the mal function table contact your WhisperPower Service Centre or WhisperPower Netherlands tel INT 31 512 571550 www whisperpower eu e Motor RPM suddenly rises or drops e Unusual noise comes from generating set e Exhaust gases suddenly colour dark e Engine failure warning light is on 32 December 2010 M SC6 8 10 EN gt TROUBLE SHOOTING 5 3 SPECIAL PROCEDURES ALTERNATOR 5 3 1 Residual voltage check excitation procedure When residual magnetism disappears there is no residual voltage Residual magnetism can disappear after the generating set being out of service for a long period or suffered a short
29. RTS LIST GE 6 SPARE PARTS LIST A parts manual in English is available as an option number number 40200381 M SC6 and 8 40200382 M SC10 A work shop manual in English is available as an option number 40200171 We recommend the following spares for service and maintenance Kit A parts for regular maintenance parts M SC6 8 and 10 marked article no 40201860 Kit B parts for maintenance spare parts M SC6 and 8 all parts market article no 40201861 Kit C parts for world travellers all parts market M SC6 and 8 article no 40201862 Kit B parts for maintenance spare parts all parts market M SC10 article no 40201761 Kit C parts for world travellers all parts market M SC10 article no 40201762 ARTICLE NO DESCRIPTION 40209030 Fuel filter 50201060 Fuel lift pump 50203120 V belt 40203121 Oil filter 50201850 Raw water pump complete WhisperPower type M refer to fig 26 40209011 Impeller gasket 4 3 5 40201812 Cover type M 2 50209018 Bolts cover 1 6 pcs 40201851 Pump repair kit A consisting of Shaft 50201811 Bearings 2 pcs 50209014 O ring 50209017 Seals 2 pcs 50209015 Clips 1 set 50209019 O ring 50201814 40209010 Pump repair kit B same as repair kit A excluding the
30. WHISPERPOWER EU fast moving parts 38 December 2010 M SC6 8 10 EN SPARE PARTS LIST 16012209 IN HATTIN 09810208 11060206 Nr 41810206 51060206 erogozog 060205 61060206 T QN 61060206 SN 61810206 N 0 0 S 02060206 91060206 9 IR 71810208 16012206 71060205 Fig 27 Water pump type M 39 EN M SC6 8 10 December 2010 MAINTENANCE LOG GE MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks 40 December 2010 M SC6 8 10 EN GE NOTES NOTES EN M SC6 8 10 December 2010 41 NOTES GE NOTES 42 December 2010 M SC6 8 10 EN GE NOTES NOTES EN M SC6 8 10 December 2010 43 Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl
31. and replace Sooty black exhaust e Generator is being overloaded Digital Diesel Control will indicate HIGH CURRENT Check electrical load and switch off some consumers e Insufficient intake air e Choked air filter Check intake air paths and filter clean and replace if necessary e Fuel injector faulty Replace injector e Valve clearance incorrect Readjust valve clearance e Poor fuel quality Use better quality diesel e Poor quality lubricating oil Use better quality oil Continuous running with very low load Increase load and have the engine run for a few hours Loss of power Wrong measurement Check if the load is measured correctly Does the Amp meter show the correct value When calculating the load by multiplying voltage and amps this should be done by using the exact values taking into account the power factor of the consumers When any doubt measure the power directly with an appropriate instrument Overfull oil sump Bring the oil to the correct level e Choked fuel filter Replace the fuel filter Choked air filter Check air inlet openings clean air filter e Exhaust blocked Check the exhaust system Injector blocked e Loss of compression sticking or damaged piston ring Have the injector checked Have the compression measured Clean or replace the rings EN M SC6 8 10 December 2010 31 T
32. arrow on the filter housing indicates the direction of the flow A clogged filter results in a lack of output of the generating set 4 2 5 Replacing oil filter The oil filter is in front of the service side Replacement has to be executed according to the schedule in this manual Drain the oil using the sump pump and put some tissues under the filter Figure 16 23 MAINTENANCE A smeer of oil has to be put on the seal of the filter before 4 3 fitting the filter The filter should be fastened manually when the rubber touches the metal turn 3 4 further CHECK DAILY Take care the oil level is never below the mark Do not oil when the level is still above the mark 1 Minimum oil level 2 Maximum oil level REGULAR MAINTENANCE Oil level see fig 19 Fig 19 CHECK DAILY e Level cooling liquid Figure 17 e Hoses for loose connections or deterioration e Water inlet filter 4 2 6 Readjustment of the V belt The alternator bracket allows for readjust of the V belt AFTER FIRST 50 HOURS Deflections should be 10 mm refer to fig 18 e Change oil and replace the oil filter Figure 18 Have the engine run until it is on temperature and stop it Drain oil by the sump pump into a suitable retainer and fill up with fresh oil Start the engine again and have it run for 5 minutes Stop the engine again and pause for a few minutes to let the oil gather in the crankcase Check the level again and add oil when necessary
33. cal system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery Warning signs indicate parts which could be 2 live EN M SC6 8 10 December 2010 2 1 3 Earth insulation failures According to local regulations and depending on the application it could be necessary to take measures for protection against earth insulation failures In the standard delivery neutral and ground are not connected To make a connection between neutral and ground could be necessary as part of a specific insulation failure protection system Small pleasure craft in Europe is submitted to Recreational Craft Directive 94 25 EC The guidelines of this directive refer to ISO 13297 When the installation complies with this standard the neutral and ground should be connected on the generating set Be aware that insulation protection systems can be different for different applications and even within the ship there could be different standards for different spaces We did refer to the Recreational Craft Directive that applies to pleasure craft up to 24 m of length Sometimes one has to comply with other standards such as the rules of certification societies like Lloyds Register of Shipping or Veritas regulations for the protection of personal building legislation etc It is of the greatest importance to have expert advice on this issue In all situations the transfer swit
34. ce faulty parts Engine speed drops e Faulty electronic governor only if applied Replace faulty parts e Too much oil Drain oil to proper level e Lack of fuel Check fuel supply system fuel pump and filter e Lack of intake air Check air intake e Choked exhaust system exhaust blocked rubber exhaust hose kinked Check exhaust system e Generator overloaded Reduce the electrical load switch off some consumers e Generator over energised e Defective generator windings bearings or other Check that the proper capacitor type is installed and that it is connected correctly Generator must be sent to manufacturer for repair of damaged bearing or winding e Damaged engine Repair by WhisperPower service Engine does not stop on command e Fuel solenoid is not switching off e Loss of control Faulty Digital Diesel Control unit Stop the engine manually by the stop handle Check wire connections to stop solenoid Check solenoid valve function Replace if necessary 30 December 2010 M SC6 8 10 EN gt TROUBLE SHOOTING PROBLEM CAUSE SOLUTION Engine exhaust smokes e Faint blue smoke generally the result of light load Increase load e Heavy blue smoke caused by lubricating oil Overfull oil sump or worn cylinder bore stuck broken or worn rings Check the oil level Check the compression e Black smoke incom
35. ches between A shore inverter and generator should switch both neutral and L1 Of course this is the case when using a Masterswitch 2 1 4 Installation Whisper generating sets are not self contained and have to be properly installed in enclosed areas such as a machine room Installation includes measures to be taken to A outlet exhaust fumes which contain carbon monoxide and are extremely dangerous Carbon monoxide CO is an invisible odourless gas Inhalation produces headache nausea or death Installation includes measures for proper ventilation safe electric connections safe installation of the starting battery proper fitting of the cooling system and fuel pipes etc Refer to the installation manual INFORMATION gt 2 1 5 Operation External moving parts like fans and V belts are covered by the canopy and therefore the Whispers are very safe when the canopy is closed Nevertheless take note of the signs on the generating set which show symbols in a triangle indicating danger When service has to be carried out while the A engine is running be aware of moving parts like V belts e The generating set should be operated by authorised personnel only e Be aware of hot parts and especially parts of the exhaust system and the cooling system e If the generating set is unsafe fit danger notices and disconnect the battery positive lead so that it cannot be started until the condition is corrected not
36. circuit This can be solved by charging the capacitor flashing independently with a small 9 Volt battery This can be done while the engine is stationary and the wiring is connected If the generating set battery is used for A flashing one must take care A short circuit can cause heavy sparking fire and injuries When flashing does not bring back voltage the capacitor s should be renewed When this does not help the rotating rectifier diodes should be tested and a winding resistant test should be executed EN M SC6 8 10 December 2010 5 3 2 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter When the diode is faulty the alternator will not generate any voltage DIODE Fig 21 The flexible lead connected to the diode should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replace the diode 33 TROUBLE SHOOTING ED 5 3 3 Winding resistant values If after establishing and correcting any fault on the capacitor and diodes output is still low when separately excited then the main rotor stator and exciter stator winding resistance should be ch
37. d the rated generator peak output current This could be remedied by providing stronger capacitors to the motor or using a soft start Inquire at your nearest WhisperPower dealer or directly at the manufacturer WhisperPower in the Netherlands 28 December 2010 M SC6 8 10 EN gt TROUBLE SHOOTING 5 2 ENGINE FAULTS Remove 3 Amp fuse in the control panel A while working on the generator to prevent the engine from starting 5 2 1 General Most electrical problems relating to Voltage or Frequency are due to wrong engine speed Note that RPM and Hz are basically the same Use the problem solving table to find the cause of a wrong engine speed When there is no obvious cause one can adjust the RPM refer to special procedures When the engine is not cranking well starting problems almost always originate from battery problems or poor battery cable connections Failure code Problem When the engine is cranking well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes When the engine does not start instantly A prolonged cranking can fill up the exhaust system with cooling water because of the water injected exhaust When the water enters the cylinder through the valves this will bring severe damage to the engine When the engine does not start and repeated cranking is necessary shut off the seawater inlet Open the valve immediately after the engine has started
38. djust valve clearance Replace the oil filter Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 hours Isolate the fuel supply and change the element EVERY 1000 HOURS Replace the V belt e Retighten cylinder head bolts adjust valve clearance EVERY 2000 HOURS e Check lubricating oil pressure e Clean and check or replace fuel injector nozzles and check injection pressure e Check the air filter element The air is taken in via the cover on the alternator Below this cover is a spongy material which filters the air and holds some electrical components which are cooled by the inlet air This filter does not require regular maintenance Only in very dusty circumstances this filter should be cleaned The spongy material can be washed in solvent or replaced e Check the cooling system The engine cooling liquid is indirectly cooled by raw water via a heat exchanger The alternator is cooled by seawater which is pumped by the PTO driven impeller pump through the cooler elements in the generator housing All parts of the cooling system are of corrosion free and seawater resistant materials such as brass and gunmetal In case of gathering of dirt in the system it could be cleaned by compressed air When overhauling the engine one could clean the parts thoroughly or replace When the generator set runs less than 100 A hours a year the oil should be changed yearl
39. e that the engine may contain some residual oil due to testing at the factory While filling check the lubricating oil level by means of the engine oil dipstick Do not overfill with lubricating oil as this may have a detrimental effect on engine performance 4 Oil pressure Minimum at idle 49 0 5 kgf cm2 7psi e Normal at 3000 rpm between 147 and 490 1 5 up to 5 kgf cm2 21 up to 71 psi e Minimum at 3000 rpm 98 1 0 kgf cm 2 14 psi 2 5 2 Cooling liquid The engine is cooled by cooling liquid The capacity of this system of the M SC6 8 is 2 litres and of the M SC10 3 5 litres Always use coolant which is compatible with A aluminum components of the cooling system Do not mix coolants with different kinds of chemical compound as this may cause congelation of the coolant In case of doubt refresh the content of the entire cooling system We recommend not using water but cooling liquid that is marketed for the use in combustion engines Cooling liquid protects the engine against frost to minus 25 C Also it protects the engine block against corrosion One can fill the engine via the filling cap on the exhaust manifold Fill up till the level is just below the filling cap When the engine is on temperature the liquid will expand and the 14 December 2010 M SC6 8 10 EN gt INFORMATION redundant liquid will be pressed into the expansion tank This tank has to be filled up till
40. ecked as the fault must be in one of these windings The respective leads must be disconnected before taking the readings Resistance values should be within 1096 of the values given in the table below M SC6 and 8 Resistance 50Hz e Resistance both main stator windings 0 54 Ohm in series e Resistance both rotor windings 0 93 Ohm e Resistance exciter stator winding 1 4 Ohm M SC10 Resistance 50Hz e Resistance both main stator windings 0 36 Ohm in series e Resistance both rotor windings 1 05 Ohm e Resistance exciter stator winding 0 85 Ohm 5 3 4 Meggering One can try to measure resistance between the housing and the windings with a multimeter which should read infinity When readings are infinity but a fault is suspected one can do a high voltage resistance test MEGGERING This procedure should be carried out by an expert 5 4 SPECIAL PROCEDURES ENGINE 5 4 1 Setting the RPM RPM is set by the manufacturer and should not need readjustment However a very slight offset after running in could occur RPM can be measured by a frequency meter M SC8 and 10 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 If readjustment of the RPM is necessary please contact your WhisperPower Service Centre for advice M SC6 Before readjustment check any other explanation for the wrong speed Engine speed is set at the
41. in this manual and according to European Community safety regulations During production and prior to delivery all of our generating sets are tested and inspected The correct functioning of this generating set is subject to guarantee The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries for the North of the Netherlands number 01120025 are available on request The guarantee period is two years limited to 1000 running hours Some aspects of our guarantee scheme are given here in more detail Guarantee period 1000 running hours or 24 months whichever occurs first Warrantee does not cover failures that are caused by misuse neglect or a faulty installation December 2010 M SC6 8 10 EN ED INTRODUCTION Example 1 Faulty installation Seawater entering the engine is the most common cause of damage to combustion engines in boats Both to propulsion and generator engines The entry of water must be avoided under all conditions Be aware that the conditions in blue water sailing can be extreme Refer to the installation manual for instructions but remember these are for guidance only as many factors influence the installation of a generator The ultimate responsibility will always be with the owner to ensure a safe and compliant installation If in doubt ask DAMAGE CAUSED BY THE INGRESS OF WATER IS NEVER COVERED BY WARRANTEE
42. ives the nominal maximum continues load in kVA kW calculated with power factor one When calculating a load one should always take into account the power factor or cos phi of this load The power should never exceed the nominal power as shown on the identification plate Power is rated at an ambient temperature of 40 and a seawater temperature of 25 For higher temperatures the generating set has to be derated 3 VOLTAGE shows the nominal voltage This voltage should be within the specified tolerance at the nominal frequency 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 3000 rpm 60 Hz correlates with 3600 rpm 5 CURRENT shows the maximum current that is acceptable at the specified frequency voltage and power factor 6 WEIGHT shows the net dry weight approximately in kg This is without fuel oil packing and external installation equipment 7 CE symbol shows that the generating set is build according to European Community safety regulations This includes the regulations regarding the safety of pleasure craft machinery electric safety and electric magnetic compatibility EMC and other relevant directives Safety also relies on the installation application and circumstances See also the remarks in this manual under SAFETY Before changing a factory setting you are advised to consult the manufacturer When the generating set you have to identify is no
43. ll with preservation oil Stop the engine and take loose the inlet of the raw water pump Drain the water from the water lock Crank the engine having the raw water inlet sucking anti freeze from a can until the pump heat exchanger and manifold are filled 5 coolant can stay in the engine 6 Disconnect the battery and store it in a place free of frost and dry and charge it regularly 7 Close inlet and outlet openings with tape 8 Protect the generating set against the influences of bad weather conditions This method of preservation will be sufficient for 6 months Repeat steps 2 3 and 4 every 6 months Change oil before using the engine again 26 December 2010 M SC6 8 10 EN TROUBLE SHOOTING 5 TROUBLE SHOOTING 5 1 ALTERNATOR ELECTRICAL FAULTS A Beware of parts which are live Remove 3 Amp Fuse in the control panel A while working on the generator to prevent the engine from starting A failure code is displayed when a hardware failure at the generator is detected 5 1 1 General If any problem should occur check basic conditions and examine all external wiring switch gear and circuit breakers Also check if measuring instruments give the correct value If in doubt measure directly on the alternator terminals with an independent instrument These measurements should only be carried out by an experienced electrician If during these measurements the engine immediately stops after sta
44. load less than 210V 105V In no load condition it is ok e Generator is overloaded e Engine is not reaching the rated RPM Switch off a load part off consumers Refer to engine RPM problems e Defective capacitor Check capacitor and replace if necessary refer to special procedures e Defective voltage regulator Optional for M SC8 10 Replace voltage regulator Generator voltage too high more than 245V 130V e Engine is running too fast RPM too high Check engine speed and adjust refer to special procedures e Over energising due to defective capacitors Check capacitor specification and replace capacitors if necessary e Presence of a strong capacitive load leading power factor e Defective voltage regulator Optional for M SC8 10 Compensate for this capacity and seek for experts advice WHISPERPOWER customers service Replace voltage regulator Generator voltage fluctuates e Disturbances on the electrical system user side Check if electrical load is fluctuating e Engine runs irregularly When engine runs irregularly refer to section Engine runs irregularly Generator is not able to start an electric motor If the generator is unable to supply enough power to start an AC electric motor this is usually because this motor draws too much current during starting Check the electric motor s current draw required for starting This should not excee
45. lockwise of T D C 35 TROUBLE SHOOTING 543 Measuring exhaust backpressure The exhaust system must be of adequate size 1 5 8 40 mm and maximal length refer to installation manual When any doubt backpressure has to be measured An easy way to measure for back pressure is to use a water column A water column can be made visible in a plastic tube along a yardstick and fitting the end to a hose connection to fit in the adaptor on the injection bent after removing the exhaust temperature switch 69 27INCHES Figure 25 Measuring exhaust backpressure The bent A hanging down should not be to short helping to damp the pulsating effect of the gas discharge that is characteristic for a one cylinder engine The water column should be no more than 27 inches 69 cm of water 1 PSI 0 07 bar 5 4 4 Disassembling instructions It could be necessary to disassemble the generating set for repair or checks Following instructions will help 1 To take the generating set out of the canopy all hose and cable connections have to be taken off The set is fixed to its base by four rubber mountings and can be loosened by removing the four nuts from the bolts of these mountings Moreover the generating set is fixed by 2 fail safes which prevent the generating set from getting loose if the rubber mountings should break down The nuts of the fail safes are diagonal to each othe
46. nected if the standard length does not suit the required distance Numerous remote control units can be put in parallel by using the connectors on the back of the units Refer to installation instructions 2 5 8 Hour counter The remote control offers several timer functions that help to schedule maintenance 2 5 9 Load indicator On the remote control the load will be indicated on the display and by the LED bar The load is measured by a current transformer on the alternator 2 5 10 Fuel specification The engine must only be used with diesel fuel oil which conforms to the standards for use in modern diesel engines Fuel free from water and contaminants is of the utmost importance 2 5 11 Oil information 1 Specification The oil must be suitable for oil changes as specified in the maintenance chapter The engine must be run on heavy duty lubricating oil meeting the requirements of API class CD CF or 4 It is very important to use the correct oil A specification Very often local oil suppliers recommend a higher class because they assume that a higher class is allowed This is not the case One should not follow these recommendations Using the wrong specification will cause high oil consumption 2 Oil viscosity We recommend a multigrade oil 15W40 3 Oil capacity Excluding the oil filter the content of the crankcase of the M SC6 8 is 2 4 5 10 3 6 Including the oil filter it is 2 9 M SC10 4 1 Not
47. ng set up to maximum have it run warm Continuous load should be restricted to 70 96 of maximum load AUN Stopping generator 1 Switch off all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load and let it run for approx 5 minutes 2 Press the STOP button Close the inlet sea water cock 4 Switch to another AC power source if available 1 Maximum oil level 2 Minimum oil level Fig 14 3 2 OPERATING INSTRUCTIONS 3 2 1 Summarised operating instructions daily use Routine pre start checks 1 Check oil level refer to fig 14 2 Engine cooling system all valves open 3 Power source selector Switch off shore power generator power Switch to power source switch OFF or switch off all consumers in the usual way 4 Switch on battery switch when installed 5 Fuelvalve open Starting Push the start button to initiate the full automatic starting procedure You can monitor the procedure on the display 20 December 2010 M SC6 8 10 EN gt OPERATION 3 2 2 Extended operating instructions Check when starting the first time or after a longer period of rest 1 If there is any damage caused by transport or installation 2 Check if installation conforms to the installation instructions 3 Ensure the generating set is free to turn withou
48. oltage 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 MAX INPUT 250 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the fuel pump without levers and other mechanical transmissions 2 microprocessor keeps the speed at the set value by controlling the actuator The microprocessor is programmed at the WhisperPower 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 WhisperPower 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 LOCAL CONTROL PANE Mass 9 fo PUMP 1 Bu Fs DDC FUEL
49. plete combustion caused by Overload choked air filter inlet temperature too high unsuitable fuel or water in fuel Check the fuel Check for overload Engine starts but stops after 10 up to 30 seconds Engine stops by itself e Protection system stops the engine this can be caused by oil pressure failure lack of cooling water exhaust temperature alarm Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure e Overload or short circuit Refer to paragraph 2 5 5 and 3 2 2 for information on the alarm system Bypassing the switches can help to confirm the failure Switch off the consumers and test for short circuit e Lack of fuel Check fuel supply system fuel lines pump filter valves tank level etc e Oil pressure low oil pressure switch tripped Check oil level Check engine s oil pressure and have it repaired by WhisperPower e Excessive heat in cooling system thermo switch tripped e Lack of cooling water exhaust switch tripped e Impeller broken Cooling water blocked e Water strainer blocked e Air or water in the fuel e Blocked air or fuel filter Check cooling water system flow water pump inlet water filter coolant flow e Loss of compression by wear out or damage Repair by WhisperPower service V belt broken or loose Readjust or replace V belt e Thermostat faulty Check thermostat
50. quest Starting battery optional Fuel consumption 60 90 Ah 12V 1 5 4 litre hour load dependent Control Digital Diesel Control including automatic start stop ELECTRICAL SPECIFICATIONS Output voltage 230V 50 Hz alternating current AC single phase Output rating at powerfactor cos phi 1 5 kW 6 4 kW 9 4 kW Voltage tolerance 5 5 5 Frequency tolerance 5 1 1 Alternator brushless two pole synchronous Voltage regulation capacitor capacitor AVR option capacitor AVR option MECHANICAL SPECIFICATIONS Supply includes generating set built into tugged GRP sound shield with steel base plate mounted on rubber anti vibration mounts Dimensions hxwxd 660x495x550 mm 660x495x550 mm 810x525x615 mm Colour top white bottom green Weight including canopy 178 kg 182 kg 210 kg Max installation angle 25 degrees 25 degrees 25 degrees Standard supplies remote panel 15 m cable fuel lift pump expansion tank Optional mobile Installation kits mobile vehicle version non earth return spare part kits Electronic governor EN M SC6 8 10 December 2010 15 INFORMATION 2 5 14 Wiring codes and colours number colour cable code no cross section battery gt starter motor red 25 mm2 starter motor DDC 1 red 6 mm2 starter motor LCP 13 red
51. r When the 6 nuts in total are removed the generating set can be lifted out the canopy 5 nuts are well accessible The sixth nut has to be removed by taking out the bold from the bottom of the canopy 2 The easiest way to get the generator out of its capsule is by lifting the set using the lifting eye and removing the capsule downwards 3 The cooler elements are welded to the alternator housing with silver and cannot be disassembled How ever one can take off the complete alternator housing 4 Before the alternator can be taken off one has to take out the fitting to the oil cooler to be able to take off the aluminium housing All cables and wiring have to be loosened first 5 The rotor can be taken off by removing the bolt which goes through the shaft normal clockwise threaded The end of the shaft is specially threaded to push off the rotor from the conic stub shaft which is on the flywheel using a 6 mm rod of 165 mm M SC6 and 8 185mm M SC 10 length and a M10 bolt 6 Reassembling the generating set one should take care of alignment cleaning the surfaces between engine and alternator and tighten the bolts crosswise and gradually 7 Use Loctite 577 to seal the fittings which should first be cleaned and made free of oil and grease 8 Test the generating set first outside its capsule and check very carefully for leakages before putting it back in its enclosure 36 December 2010 M SC6 8 10 EN SPARE PA
52. r a major overhaul In the first 50 hours the engine should receive special attention Long periods of light or no load running in the first 50 hours may lead to cylinder glazing and high oil consumption For the same reason it is of the greatest A importance to use the right oil specification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel lines Ensure there is sufficient fuel The system is self bleeding The first time starting up or after running out of fuel it could be necessary to prime the fuel system Push the start button activating the electric system and activating the fuel pump When more time is needed to bleed push start and hold on the local control panel so not on the remote panel Hold as long as necessary to bleed the system Retighten the bleed screw when no further air bubbles are expelled EN M SC6 8 10 December 2010 Figure 15 Bleeding fuel lines 1 Fuel bleeding screw 4 2 3 Valve clearance When the engine is in cold condition both valves inlet and outlet should have a clearance between 0 25 mm The adjustment has to be done at TDC refer to 5 4 2 4 2 4 Replacing fuel filter Filter change depends on contamination of the fuel but should be done however at least every 1000 running hours Before changing the filter clamp off the supply line Remove the hoses from filter and attach them on the new filter again The
53. r at least one hour in 10 hours for minimum 70 Long term running at too low load will cause the exhaust to be choked by carbon Never remove the battery while the engine is A running or any electrical cable while the battery is connected in the circuit Only disconnect the battery with the engine stopped and all switches in OFF position Stopping the generating set 1 Avoid stopping of the generator abruptly after a long period of operation at high load Doing so you avoid unnecessary thermal load to your generating set Act as follows Prior to switching off the generating set decrease the generator load i e turn off most electrical users and let the generator run at low load for approx 5 minutes to allow the engine to get properly cool the influent sea water must flow through the system in order to cool the engine If the generator is operating in a hot environment and you do not act as given above the excessive heat in the engine can trip the high temp alarms In that case a restart of the engine is not possible for some time It is also recommended to switch off electrical users prior to stopping the generator because of the voltage drop that occurs as the engine comes to a halt Such voltage drops may cause damage to electric motors compressors in refrigerators or air conditioners etc 2 Press the STOP button 3 Close the inlet sea water cock 4 Switch to another 230V power source if available If a
54. rating set in specific conditions which brings dangers which could not be foreseen or could be avoided by additional measures WhisperPower does not accept liability for damage due to use of the generator possible errors in the manuals and the results thereof Automatic start stop WhisperPower cannot be held responsible for damage caused by the unattended running generator using the auto start stop mode or interval mode INTRODUCTION ED 1 5 IDENTIFICATION 1 5 1 General Before using this generating set it is very important to identify the set correctly To communicate for service or ordering parts it is also essential to correctly identify the generating set Also for the daily operation of the genera ting set it is necessary that the operator knows the correct specifications 1 5 2 Identification plate All required identification data are on the identification plate For location of the identification plate see figure 1 gt MODEL SERRA NO LTAGR CURRENT pm YEAR OF MANUFACTURING Manufacturer Whisper Power BV Kelviniaan 42 3207 JB Drachten The Netherlands Tel 31 12 671550 Figure 1 Location identification plate 1 The identity of the generating set is given by the SERIAL NUMBER When this number is available the manufacturer can trace the specifications of the generating set On the identification plate are also some basic features of the set 2 POWER The identification plate g
55. rpm and provides voltage fall off with speed preventing over excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine The M SC8 and 10 can be equipped with an optional voltage regulator to keep the voltage tolerance within 296 Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 252 Engine The M SC6 and 8 generating set is based on the Mitsubishi L2E 2 cylinder diesel engine The M SC10 on the L3E 3 cylinder The engine is indirectly injected The engine is oil cooled and the oil is cooled by a heat exchanger and raw water The heat exchanger and all other parts which are in direct contact with the raw sea water are made of seawater resistant material like naval brass and gunmetal The engine has been specially adapted for the WhisperPower application and is very different from the standard engine supplied for industrial applications 2 5 3 Digital Diesel Control system The standard electrical engine control system is 12 Volt negative earth non earth return ungrounded is available as optional Check your identification data to determine which system is applied The system is designed according to the energise to run system The Digital Diesel Control is a very advanced microprocessor based full automatic system Besides automatic start the system offers many monitoring options Refer to the separate Digital Diesel Control
56. rting and an error code is displayed at the remote control panel AC VOLTAGE one can start the generator by means of a service start at the service Failure code Problem menu see paragraph service start of the users manual of the Digital Diesel Control By doing this the generator will keep running for 2 minutes before it stops This offers you the possibility to out measurements to investigate the cause of the failure Check if the engine is running correctly at 3000 RPM 50 Hz according to its settings and does as well under load e M SC6 A RPM drop of 5 at full load is acceptable Therefore a no load setting should be at 3150 RPM 52 5 Hz Under no circumstances should the RPM under full load be below 2940 RPM 49 Hz M SC8 and 10 RPM drop of 1 at full load is acceptable Therefore a no load setting should be at 3030 RPM 50 5 Hz Under no circumstances should the RPM under full load be below 2970 RPM 49 5 Hz When the problem is in the RPM refer to the engine fault finding paragraph Digital Diesel Control system will help to indicate failures and display causes COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage EXHAUST TEMP Exhaust temperature is too high WATER TEMP Coolant temperature is too high OIL PRESSURE Oil pressure failure AC VOLTAG
57. shaft 50201811 and O ring 50201814 50201820 Heat exchanger complete with appendages M SC6 and 8 50201822 Water hoses with clamps M SC6 and 8 50201720 Heat exchanger complete with appendages M SC10 50201722 Water hoses with clamps M SC10 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50101886 Alternator bearing including O ring Voltage regulator M SC8 and 10 optional 40209161 Local control panel 50209146 Digital Diesel Control Unit 50212170 Fuses 10 Amps 50212154 Fuses 3 Amps 50201886 Wiring loom complete 40209102 Digital Diesel Remote control panel 50209133 Cable remote control 15 mtr including connectors 50203033 Overhaul gasket kit Sealkit M SC6 and 8 50203030 Cylinder head gasket kit M SC6 and 8 50204033 Overhaul gasket kit Sealkit M SC10 50204030 Cylinder head gasket kit M SC10 50203040 Glow plug 2 pcs M SC6 and 8 3pcs M SC10 50203050 Nozzle injector 2 pcs M SC6 and 8 3pcs M SC10 50203160 Fuel pump high pressure complete M SC6 and 8 50204160 Fuel pump high pressure complete M SC10 50203045 Thermostat 50203038 Gasket thermostat 50203037 Gasket rockercover M SC6 and 8 50204037 Gasket rockercover M SC10 50209051 Silicone O ring soundshield cover More extensive parts list on the internet
58. spare parts as well as a chapter on maintenance and problem solving 2 3 4 Accessories included in the standard delivery e Special hose connector for measuring exhaust backpressure e Expansion tank hose and fittings INFORMATION ED 2 4 COMPONENTS 241 Main components to identify 01 02 03 04 05 06 07 Mi Sees A S 4 Em 25 18 19 20 21 Figure 3 Front view main components 5 6 8 10 Fuel injection pump Fuel injector M SC6 2x M SC10 3x Glow plug M SC6 2x M SC10 3x Alternator 12VDC Engine oil dipstick Coolant drain plug Oil sump hand pump Air cleaner element Control panel Fuses Digital Diesel Control DDC Identification plate Hoist eye front Injection pump air bleeding screw Engine speed adjustment Screw Fuel solenoid Raw water pump Fuel lift pump Engine oil filter 10 December 2010 M SC6 8 10 EN INFORMATION Figure 4 Rear view main components M SC6 8 Figure 5 Rear view main components M SC6 8 EN M SC6 8 10 December 2010 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Cooling water injection bend Temperature switch exhaust Heat exchanger Starter motor solenoid Starter motor Rubber engine mounting Fuel in 8mm
59. t obstruction 4 Check all hoses and hose connections for leaks Check all cables and cable end terminal connections 6 Check the engine and generator mounting bolts Routine pre start checks 1 Check engine oil level The generator switches off in the event of insufficient oil pressure Even when the oil level is too low the oil pressure can be high enough Do not run the generator with the oil below the lowest mark in the because a smaller volume of oil will become contaminated considerably quicker than a larger volume Therefore we recommend daily oil checks Check oil level prior to starting the engine or at least 5 minutes after the engine has stopped 2 Check sea water cocks Do not forget the valve of the water outlet in case of a water exhaust gas separator 3 Check the water strainer 4 Check for leaks 5 Regularly check the siphon vent in the cooling water supply 6 If no Masterswitch is used Switch main Power Source Selector switch to OFF or switch off all devices 7 Switch on the battery switch Starting the generator By pushing the start button briefly the electric system is activated the fuel lift pump starts pumping and the starting procedure will begin By pushing the stop button the system is deactivated The first time starting up or after running out of fuel it could be necessary to prime the fuel system Refer to bleeding fuel system instructions in the maintenance chapter EN M SC6 8 10
60. t new you have to take into account the possibility that former users may have changed the settings Check the settings voltage frequency rpm when there is any doubt December 2010 M SC6 8 10 EN ED INFORMATION 2 INFORMATION 2 1 SAFETY 2 1 1 General When correctly installed and used in normal circumstances this generating set fulfils EC safety regulations This generating set could be part of an installation or could be used in a way that additional regulations of the EC or other authorities have to be taken into account Circumstances could make it also necessary A to take additional measures Be aware of wet conditions and hazardous environments caused by explosive gases etc 2 1 2 Electrical safety The voltage of 230 Volt generated by this generating set is dangerous and if instructions and procedures are not strictly observed may result in electrical shock which will result in severe personal injury or loss of life e Check all wiring at least once a year Defects such as loose connections burned cables etc must be repaired immediately e Do not work on the electrical system if it is still connected to a current source Only allow changes in your electrical system to be carried out by qualified electricians e Connection and protection must be done in accordance with local standards e Using the auto start stop interval mode the generator can start unexpectedly When working on the electri
61. tch to power source generator Before loading the generating set up to maximum have it run warm The first 50 hours of running the continuous load should be restricted to 70 of maxi mum load Running for long periods at no load or light load in the first 50 hours can cause cylinder glazing and high oil consumption 21 OPERATION Engine load during longer operation Please ensure that the generating set is not overloaded Overloading occurs when the electrical load demand is so high that the generator cannot be turned around properly by the diesel engine Overloading causes the engine to run rough while using oil and excessive fuel and producing soot by the exhaust The engine can even stop The generator should therefore only be loaded at the maximum rated power for short periods 2 3 hours only The high peak current is meant for the ability to start electrical devices that need a high current for starting especially electric motors and compressors from a still stand state In order to prolong the generating set s life expectancy the nominal electrical demand on the system should be about 70 or the rated generating set s maximum load Please note this when switching on your electrical devices Nevertheless the M SC6 8 10 is designed so as not to overheat even under extreme conditions Do not run the generator for very long periods at no load or at very low load When this is necessary do load the generato
62. the mark When cooling liquid is not available clean fresh water could be used with an additive of anti freeze When using water with anti freeze the right mixture has to be calculated according to the information of the supplier of the anti freeze When the cooling is based on keel cooling or radiator cooling the capacity of these coolers and piping has to be taken into account calculating the right mixture The cooling liquid in the engine is pressurised and has a boiling point above 100 C The temperature switch in the thermostat housing switches at 110 C When keel cooling or radiator cooling is applied the cooling system is not pressurised There should be a special cap on the manifold without valves leaving the connection to the expansion tank open Refer to the manual on keel cooling and radiator cooling 2 5 13 Technical data Model M SC6 M SC8 M SC10 GENERAL RPM 3000 3000 3000 Alternator water cooled synchronous Engine Mitsubishi diesel model L2E L2E L3E Number of cylinders 2 2 3 Displacement 635 cm3 635 cm3 952 cm3 Bore X stroke 76x70 mm 76x70 mm 76x70 mm Combustion air consumption 0 9 m3 min 0 9 m3 min 1 4 m3 min Continuous power engine 5 kW 6 4 kW 10 5 kW Cooling system indirect cooling by raw water 10 15 l min Cooling water pump PTO driven WhisperPower self priming impeller pump type M Fuel lift pump engine electric pump 12 V DC additional pump available upon re
63. y EN M SC6 8 10 December 2010 4 3 1 Maintenance schedule Check oil level daily Check water inlet filter daily Check the level of the cooling liquid daily Change oil and oil filter after first 50 hours Check and tighten nuts bolts etc after first 50 hours Check exhaust after first 50 hours Check air vent after first 50 hours Check and readjust V belt after first 50 hours Check electrical connections after first 50 hours Change oil 150 hours Check battery 150 hours Check air vent 150 hours Check and readjust V belt 150 hours Check impeller water pump 150 hours Replace impeller water pump 300 hours Retighten cylinderhead bolts and readjust 300 hours valve clearance Replace oil filter 300 hours Replace fuel filter 300 hours Retighten cylinderhead bolts adjust valve clearance 1000 hours Replace the V belt 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours Check cooling system 2000 hours 25 MAINTENANCE 4 3 2 Putting out of service When not using the generating set for a longer period it is recommended to execute an engine preservation procedure Clean the engine Loosen the fuel suction pipe and fuel return and put them in a can with preservation diesel fuel Start the engine and run the engine warm Drain the hot engine oil and refi

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