Home

Whisper Power W-SQ20 Technical information

Contents

1. e Loss of compression by wear out or damage Repair by Whisper Power service Engine runs irregularly e Unsuitable contaminated fuel e Lack of fuel EN W SQ20 for mobile applications April 2010 Fill up with fuel or replace by better quality 29 TROUBLE SHOOTING 4 whisper Power PROBLEM CAUSE df SOLUTION e Choked fuel filter Check fuel filter and fuel lift pump clean or replace if necessary e Disturbances on the electrical system user side Check if electrical load is fluctuating e Faulty fuel lift pump Try the pump by manual operation Repair when faulty or replace e Choked air cleaner element e Lack of air Check the air intake e Choked exhaust system exhaust blocked Check the exhaust piping inspect manifold inside e Air in the fuel pipes Bleed air from fuel system refer to maintenance section 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 Engine speed drops 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 e Choked exhaust system exhaust blocked Check air intake Check the exhaust piping inspect manifold inside e Generator overloaded Reduce the electrical load switch off s
2. Take away the overload Fill up with coolant and release air bubbles Check if there are air blocks in the system refer to the installation manual e Radiator choked by dirt e Hot air circulation in radiator Check the cooling system thoroughly Clean radiator 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 e Unusual noise comes from generating set e Exhaust gases suddenly colour dark e Engine failure warning light is on A Generator must be shut off immediately if e Motor RPM suddenly rises or drops EN W SQ20 for mobile applications April 2010 31 TROUBLE SHOOTING 4 whisper DUTY 5 2 4 Service address If you cannot correct a problem with the aid of the mal function table contact your Whisper Power Service Centre or Whisper Power Netherlands for an extended service list tel INT 31 512 571550 32 April 2010 W SQ20 for mobile applications EN 4 whisper Power TROUBLE SHOOTING Y 5 3 SPECIAL PROCEDURES ALTERNATOR 5 3 1 Automatic Voltage Regulator AVR The voltage regulator has a 2 voltage precision in the machine working range with distortion free loads The phase voltage can be adjusted by trimmer V see figure 27 from 185 to 290V The regulator is equipped with a frequency dependant excitation limiter the frequency can be calibrated by trimmer UF whi
3. 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 In all situations the transfer switches between A shore inverter and generator should switch both neutral N and all phase lines L1 L2 and L3 Of course this is the case when using a Mastervolt Mass Systemswitch 2 1 4 Installation Whisper generating sets are not self contained and have to be properly installed in enclosed areas Installation includes measures to be taken to 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 Do not use the generator set when the vehicle is inside a building or in other enclosed area s Be aware using the generator in wind still conditions when the exhaust fumes could accumulate under around or even in the vehicle INFORMATION whisper Power 2 1 5 Operation Exter
4. Change oil for a lower viscosity e Wiring 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 motor fault Repair the starter motor Starter is turning engine smoothly but engine fails to start e Out of fuel or faulty fuel water in the fuel e Fuel solenoid is not opening no click can be heard Fill up with fuel or replace with better quality Check wire connections and circuitry to solenoid Refer to DC wiring diagram e Fuel lift pump is not working e 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 e Low compression because of dirty valves e Blocked injector 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 Whisper Power service department for advice Have the injector tested and cleaned if necessary
5. EN W SQ20 for mobile applications April 2010 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 option 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 users manual The microprocessor unit is located in the black box on top of the alternator see figure 7 2 5 4 Battery charger On the engine is an alternator generating 50 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 details will be shown on the display and the engine will be shut down There are two functions guarded oil pressure and coolant temperature All alarm switches are closed when no malfunction occurs 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 Monitoring Refer to the operating of the Digital Diesel Control 2 5 7 Control Th
6. EVERY 150 HOURS e Change oil e Check the battery acid level not applicable when Whisper Power batteries are used e Check battery terminals for corrosion e Check and readjust V belt EN W SQ20 for mobile applications April 2010 AFTER FIRST 300 HOURS e Retighten the cylinder head bolts and adjust the valve clearance Refer to 5 4 2 EVERY 300 HOURS e Check the impeller of the engine coolant pump s Replace the oil filter e Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 hours 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 500 HOURS s Check air cleaner element EVERY 1000 HOURS e Replace the V belt e Retighten the cylinder head bolts and adjust the valve clearance Refer to 5 4 2 e Check and clean the radiators EVERY 2000 HOURS e Replace or clean the air cleaner element e Check lubricating oil pressure e Clean and check or replace fuel injector nozzles and check injection pressure When the generator set runs less than 100 A hours a year the oil should be changed y
7. 0 and 230 for an output voltage between 200 and 280V EN W SQ20 for mobile applications April 2010 Jumper J Fig 27 Automatic Voltage Regulator AVR To increase the range of available voltages by about 15 use terminal Pa instead of terminal 0 Caution if the voltage is set any higher than its maximum limit the generator may be damaged Setting the bottom speed at 50 60 Hz start up rotation of the generating set adjusting it to obtain a frequency of 46 56 Hz Turn trimmer UF until the voltage begins to drop Restore nominal speed Caution if the bottom speed is set at too low a frequency the generator may be damaged On the other hand too high a frequency can cause voltage drops with high loads If on load voltage fluctuations are experienced adjust potentiometer ST which modulates the reaction time of the regulator to external inputs thereby eliminating any instability in the alternator load system 5 3 2 Residual voltage check excitation procedure flashing 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 a short circuit This can be solved by exciting the exciter field coil directly disconnecting the AVR first Put 12 Volt directly over the electronic regulator terminals taking polarity into account 33 TROUBLE SHOOTING N BLACK 12V MINUS N R
8. applications April 2010 2 3 THE W SQ20 2 3 1 Features This generating set includes a 4 cylinder diesel engine which is connected by close coupling to a tri phase synchronous 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 The complete set is again on rubber mountings All cables and hoses are guided through the capsule s sides 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 generating 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 users manual 2 3 2 Remote control The full automatic remote control panel including 15 mtr cable comes as standard with the Whisper generating set 2 3 3 Documentation Included in the delivery are e This users manual number 40200616 s An installation manual number 40200626 e A users manual for DCC number 40200261 e A quick reference guide for DDC number 50200275 Not included in the standard delivery but available as options are e Parts manual number 40200187 e Workshop manual number 40200174 However in this manual there is a list of important part
9. cooling system has to be done via the expansion tank When the engine is on temperature the liquid will expand and the redundant liquid will be pressed into the expansion tank This tank has to be filled up till the mark On the tank is an overflow connection This connection can be used to connect an open hose to drain the overflow of the cooling liquid to outside the vehicle 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 The cooling liquid in the engine is pressurised A high pressure hose connects the manifold to the expansion tank 14 April 2010 W SQ20 for mobile applications EN 5 whisper Power INFORMATION Y 2 5 14 Technical data GENERAL Model W SQ20 RPM 1500 Alternator 3 phase synchronous air cooled Engine Mitsubishi diesel model S4S Japan Number of cylinders 4 Displacement 3331 cm3 Bore X stroke 94x120 mm Combustion air consumption 10 m min Continuous power engine 24 kW mechanical power Cooling system By means of a radiator Fuel lift pump engine Mechanical pump additional electrical pump available upon request Starting battery optional 110 Ah 12V Fuel consumption 2 9 litre hour load dependent Control Digital Diesel Control inclu
10. 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 Whisper Power 30 April 2010 W SQ20 for mobile applications EN E whisper Power Y PROBLEM TROUBLE SHOOTING CAUSE SOLUTION e Excessive heat in cooling system thermo switch tripped e Lack of cooling water exhaust switch tripped e Impeller broken e Cooling water blocked e Air or water in the fuel e Blocked air or fuel filter Check cooling liquid level in expansion tank check coolant flow coolant pump Check if radiator fans work properly and switch to higher speed Air piping system might block circulation Almost all problems of overheating are caused by faulty installation bents in the routing of cooling pipes that capture air bubbles air locks or hot air circulating bacj into the radiators Refer to installation manual Check and clean e Loss of compression by wear out or damage Repair by Whisper Power service e V belt broken or loose Readjust or replace V belt e Thermostat faulty Check thermostat 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 cleaner
11. the blood stream with fatal results April 2010 W SQ20 for mobile applications EN E whisper Power INFORMATION Y e 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 2 2 TRANSPORT LIFTING AND STORAGE When lifting the generating set avoid any risk of personal injuries do not stand under the generating set e Use soft slings to avoid damage e On the engine are two hoist eyes which can be used to take the generator out of the capsule They can also be used to lift the complete generating set including the capsule 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 The alternator windings tend to condense To minimise condensation store the generating set in a dry and warm storage area e 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 W SQ20 for mobile
12. 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 Whisper Power does not accept responsibility for damage injuries or casualties which are the result of operation of the generating set in specific conditions which brings dangers which could not be foreseen or could be avoided by additional measures Whisper Power does not accept liability for damage due to use of the generator possible errors in the manuals and the results thereof Automatic start stop Whisper Power cannot be held responsible for damage caused by the unattended running generator using the auto start stop mode or interval mode 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 amp whisper P INTRODUCTION x y 1 5 2 Identification plate All required identification data are on the identification 1 The identity of the generating set is given by the plate For location of the identification plate see figure 1 SERIAL NUMBER When this number is available the manufacturer can Van trace the specifications of the generating set On the w
13. 2 7 Liftpump plunger 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 23 MAINTENANCE 4 whisper Power 4 2 4 Replacing fuel filter Filter change depends on contamination of the fuel but should be done however at least every 300 running hours A clogged filter results in a lack of output of the generating set 01 Fuel filter Fig 21 Location fuel filter cartridge 4 2 5 Replacing oil filter 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 01 Engine oil filter 02 Engine oil dipstick Fig 22 Location engine oil filter and dipstick Y A smeer of oil has to be put on the seal of the filter before fitting the filter The filter should be fastened manually when the rubber touches the metal turn 3 4 further Fig 23 4 2 6 Tensioning V belt The alternator bracket allows for readjust of the V belt Deflections should be 13 mm see fig 24 Adjusting bolt Adjusting plate Alternator pulley Mounting bolt Crankshaft pulley Fig 24 Tension V belt 4 2 7 Air cleaner element The interval for cleaning of the air cleaner elem
14. 8 April 2010 W SQ20 for mobile applications EN E whisper Power TROUBLE SHOOTING Y Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage AC ALTERN TEMP AC alternator temperature is to high generators for mobile applications only 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 engine PROBLEM CAUSE SOLUTION Diesel engine fails to crank the starter makes clicking noises or the engine cranks very slowly e Almost certainly this is an electrical problem Display will indicate LOW START BAT The problem must be an electric malfunction No reaction at all e Starter battery switched OFF Check position of the battery switch and switch ON e Faulty fuse on the control panel Replace fuse No reaction or clicking noises or slow cranking 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 Too thick engine lubricating oil
15. 9c900c0v JUV 4 whisper Power Y USERS MANUAL FOR MOBILE APPLICATIONS W SQ20 1500 RPM Mobile diesel generating set 230 400V 50Hz Digital Diesel Control Ex X gt nne nn gt WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 April 2010 CONTENTS Y CONTENTS 1 INTRODUCTION ME 4 1 1 A A n 4 1 2 Service and MAINTENANCE citaciones 4 1 3 GUAM aid ee 4 1 4 Eel 5 1 5 Ke Ein lere ore tet A EEE EE 5 1 5 1 A A E 5 1 5 2 Identification plate 2 it a 6 2 INFORMATION 0 dai cidad 7 2 1 MV iia A AA 7 2 1 1 Generali a EE 7 2 1 2 Electrical Safety eerte etie ge ede tree e pe doter ede aes 7 2 1 3 Earthuinsulation fallUres ioco ioc nii tdt 7 2 1 4 ee Ta TE 7 2 1 5 Ol ici AA pad 8 2 1 6 Fire and explosion OR 8 2 1 7 ChemicalS cocinada alee 8 2 2 Transport lifting and storage erret rem rtr dare ie 9 2 3 HUESCA 9 2 3 1 Features xi eee REED Een ich EMI EI TP LU 9 2 3 2 Remote control adi ds 9 2 3 3 Documentation rn aca 9 24 igo neam 10 2 4 1 Main components to Identify 5 5 4 1 3 rii ede iia 10 2 4 2 Generator control panel iioi stres dt RE e d d ep anne 12 2 4 3 Remote COMMO paa viii ta 12 25 Techni
16. E a DD S TR E EXT A TO CONNECT NEUTRAL TO GROUND REFER TO 2 1 3 USER MANUAL W SQ20 Fig 16 AC Wiring Diagram single phase with AVR 230V Hz Double Delta EN W SQ20 for mobile applications April 2010 19 INFORMATION amp whisper DUTY 2 5 19 Electrical diagrams radiator fan control Y En MAIN CIRCUIT i BREAKER L2 p w GENERATOR 4 AC LOAD N e A g pe E i __ CIRCUIT 4 BREAKER pl Fig 17 Electrical diagram for standard fan control E s M AIR FAN using a 230V AC radiator fan PUMP E GENERATOR 12V 230VAC L1 51 4 Q FUSE 5A 11 FUSE 6 3A 14 s5 be K1 11 15 a 16 490v FUSE 5A FUSE 5A 80 70 C H 230V 230VAC 0 TRANSFORMER NOVA OT gs A2 A2 K1 K2 A1 A1 513 14 41 Bar 09 GENERATOR K1 dl ie 12V 230VAC N 4 S THERMOSTAT COOLER i T RADIATOR COOLER ENGINE FUSE 6 3A ENGINE GENERATOR CONTACT PUMP PCB TERMINAL BLOCK 12VDC 80 70 C ul z o z iu E eo o z ra wi I BATTERY 230VAC 230VAC oc uj Q cc e O E S o w SB EZ S ad cou IZ NOU GC LU JUNCTION BOX AIR FANS LU al Ki 230VAC DIMENTION BOX 270x270x180 MM Fig 18 Electrical diagram fan control using a 230V AC radiator fan with two speeds fans optional 20 April 2010
17. ED 12V PLUS SN j Fig 28 Residual voltage check excitation procedure When using the starter battery fuse it and limit the current with a 30 Ohm resistor Flashing can be done while the engine is running and the wiring is connected When a variac variable power supply is available one should be able to control the voltage manually CAUTION A If the starter set battery is used for exciting one must take care A short circuit can cause heavy sparking fire and injuries When external excitation does not bring back voltage the rotating rectifier diodes should be tested and a winding resistant test should be executed 5 3 3 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter The diodes are integrated in a rectifier unit When all diodes are faulty the alternator will not generate any voltage When one or more diodes are faulty the alternator will produce too low voltage The flexible leads connected to the diodes 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 In case of faulty diodes replace the rectifier unit One can get access to the diode unit by tak
18. LS KEE eov TESTO 1NdINO 2v YOLWUINIS OL April 2010 W SQ20 for mobile applications EN Fig 13 Electrical Diagram control wiring W SQ20 for mobile applications 16 E whisper Yower Y INFORMATION 2 5 16 Terminal modes 115VAC 230VAC 400VAC 50Hz en OS1705 Fig 14 Terminal modes W SQ20 EN W SQ20 for mobile applications April 2010 4 whisper Power INFORMATION 2 5 17 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR TO CONNECT NEUTRAL TO GROUND REFER TO 2 1 3 USER MANUAL W SQ20 A VA o A L G ai zd dau aus de Eas EE ibo le v cu EXT A Lot p Fig 15 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR 18 April 2010 W SQ20 for mobile applications EN E whisper CDL N INFORMATION Y 2 5 18 AC Wiring Diagram single phase with AVR 230V Hz Double Delta ty mE E m A E TER TL LE tnd P
19. The voltage setting on the AVR can be adjusted with the help of a trimmer V between 185 and 290 Volts See par 5 3 1 A frequency control progressively deactivates the machine when the drive motor speed drops below a pre set adjustable threshold preventing over excitement at low operating speeds and abating the load engage effects on the engine The AVR works only within limits of the set frequency 50 Hz When operating below the lower limit of 46 Hz 1 Hz the AVR will stop regulating to avoid overloading the exciter coil This setting can be changed with trimmer UF See par 5 3 1 When applying the generator set at 60 Hz the AVR is re adjustable as well To operate at 60 Hz the engine RPM and Digital Diesel Control settings must also be changed For the USA market a dedicated manual Art No 50200444 is available for 60 Hz applications Please refer to the Whisper Power centre for specific instructions to convert the generating set to 60 Hz A further option is to readjust the stability of the regulator In the event of very irregular alternating loads it could be Fig 8 Control panel Fig 9 Digital Diesel Control unit 2 4 8 Remote control panel L_ C necessary to change this setting with the help of trimmer S to avoid interference of the regulator and the alternating load In conclusion the regulator reaction time J can be modulated to eliminate any voltage instability that u
20. W SQ20 for mobile applications EN 5 whisper Power OPERATION Y 3 OPERATION 3 1 GENERAL The generating set is operational after full installation and filling up with fuel engine lubricating oil and cooling liquid connecting the battery to earth and connecting the digital remote control panel 1 Maximum oil level 2 Minimum oil level Fig 19 3 2 OPERATING INSTRUCTIONS 3 2 1 Summarised operating instructions daily use Routine pre start checks 1 Check oil level refer to fig 19 2 Check cooling system coolant level 3 Power source selector switch off external power generator power Switch to power source switch OFF or switch off all consumers in the usual way If a Mass Systemswitch is installed this operates automatically 4 Switch on battery switch when installed 5 Fuel valve open Starting Push the start button to initiate the full automatic starting procedure You can monitor the procedure on the display EN W SQ20 for mobile applications April 2010 In operation checks 1 Check for abnormal noise or vibration 2 Check the voltage 3 Power source selector switch off external power generator power Switch to power source generator If a Mass System switch is installed this operates automatically 4 Before loading the generating set up to maximum have it run warm Continuous load should be restricted to 70 of maximum load Stopping generator 1 Switch off al
21. ation procedure flashing sse eee eee eee eee eee 33 5 3 3 Testing rotary rectifier diodes 5 3 4 Winding resistant values omnia etc bene 5 3 5 Meggerind icon dra 5 4 special procedures enging PE 5 4 1 Setting the RPM eee 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts nnee eenn 35 5 4 3 Disassembling Instr ctioris ici toten etta renati it prenne Diet agetur aande ri ERO dd he 36 6 lg ize igpadi ee L G 38 MAINTENANCE LOG 525 ten 39 EN W SQ20 for mobile applications April 2010 3 INTRODUCTION 4 whisper Power 1 INTRODUCTION 1 1 GENERAL The W SQ20 Mobile Diesel Generating set is manufactured and marketed by Whisper Power 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 Whisper Power W SQ20 generating set This manual is
22. cal formativo P 12 2 5 1 AG altertiatOr EE 12 2 5 2 Engine iz ran etae EE ERRARE DRE vedienen ORO ER bait M es 13 2 5 3 Digital Diesel Control system sssssssesese a a a enne nnn en nennen nnne 13 2 5 4 Battery charger eee eR ERE EN EE Rb nm e 13 2 5 5 Alarms arid shut AO Wicca Ege i ode ash HE P RP Ege dae ede 13 2 5 6 Monitorifig s iet a e t m Rem 13 2 5 7 eire er Cx LaC E UN 13 2 5 8 Remote COBITOL iacit icit eto tenet ip Ete Ree E reca RE Eaa ea deae be sep 2E Speak o Mana eee aan dd 14 2 5 9 Hour COUNTER 2s A A 14 2 5 10 LOA indicator tet ste ts aa wes en te to a ete a o lA as 14 2 5 11 Fuel specification nvt edere arie ee et A cde eer edn 14 2 5 12 Oil information 2 5 13 Cooling liquid E 2 5 14 Technical data 2 5 15 Electrical diagram control wiring W SQ20 nennen ennen nono nennen nennen nennen 16 2 5 16 Terminal modes 115VAC 230VAC 400VAC 50HZ eee 17 2 5 17 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR eeen 18 2 5 18 AC Wiring Diagram single phase with AVR 230V Hz Double Delta anne enen 19 2 5 19 Electrical diagrams radiator fan control see ee eee 20 2 April 2010 W SQ20 for mobile applications EN whisver Power g CONTENTS 3 OPERATION A AT A E A oke dein edenge nia densantenn dean davad enden 21 3 1 General attente rendeert et eb aaa 21 3 2 Operating Instructions temeer enen enden e ie epo rai ann a ines 21 3 2 1 Summarised operating instruction
23. ch is factory set at 46Hz 56Hz 1Hz On reaching this frequency the machine begins to reduce its voltage until it deactivates for very low frequencies A fuse protects the regulator and generator against overloads and or faults a pocket has been provided on the edge of the board to hold a spare fuse rapid type 32x6 3 2A Another trimmer ST allows to adapt the regulator to the generator parameters The regulator has been built to suppress the voltage surges on releasing the load that are below 20 at nominal load AVR SETTINGS To select the AVR settings access the control board after removing the cover Most adjustments are factory set to ensure satisfactory results in the operating tests on commissioning Further adjustments may be necessary to ensure optimum operation under specific working conditions If the alternator has to operate at 50Hz the jumper J across the terminals marked 60Hz has to be left in place if it has to operate at 60Hz this jumper should be removed The output voltage can be changed by adjusting potentiometer V Take the generating set to its nominal speed and turn until the required voltage is obtained If a small variation in speed causes a change in voltage then the bottom speed protection should first be calibrated The voltage reference orange wires should be connected e to terminals 0 and 115 for an output voltage between 100 and 140V factory setting e to terminals
24. cification The oil must be suitable for oil changes as specified in the maintenance chapter The Mitsubishi engine must be run on heavy duty lubricating oil meeting the requirements of API class CD CF or CF 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 Y 2 Oil viscosity We recommend a multigrade oil 15W40 3 Oil capacity Excluding the oil filter the content of the crankcase is 9 Including the oil filter it is 9 3 1 Do not overfill with lubricating oil as this may have a detrimental effect on engine performance 4 Oil pressure e Minimum at idle 98 kPa 1 kgf cm 14psi 1 bar e At 2230 rpm 300 kPa 3 kgf cm 45 psi 3 bar 2 5 43 Cooling liquid The engine is cooled by cooling liquid The capacity of this system depends on the size of the radiator piping and other parts in the 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 Initially one can fill the engine via the filling cap on the exhaust manifold Fill up till the level is just below the filling cap Additional filling of engine
25. ction Engine runs irregularly at the Engine faults paragraph 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 As the alternator is very much under rated the problem will appear by the engine RPM collapsing Check the electric motor s current draw required for starting This should not exceed the rated generator output current This could be remedied by using a soft start Inquire at your nearest Whisper Power dealer or directly at the manufacturer Whisper Power in the Netherlands 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 When the engine is cranking well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes A failure code is displayed when a hardware failure at the generator is detected 2
26. d to take a generator out of a vehicle or for reinstallation There is no cover for labour needed to get access to the generator for example to remove equipment or parts of the vehicle body etc Goods to be delivered under guarantee will be invoiced Only after the faulty goods are returned will the invoice 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 Printed Circuit Board is returned with clear damage caused by water 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 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 EN W SQ20 for mobile applications April 2010 If any problem arises which could be subject of guarantee procedures should be followed as described in the guarantee conditions 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
27. ding automatic start stop ELECTRICAL SPECIFICATIONS Output voltage 230 400V 50 Hz alternating current AC tri phase re connectable to take off single phase or dual voltage Output rating Whisper 20 kVA at powerfactor cos phi 0 8up to 1 Voltage tolerance 2 balanced load Frequency tolerance 13 Alternator Air cooled brushless four pole twelve wire synchronous Voltage regulation AVR MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on rubber anti vibration mounts Generator set without sound shield is optional Dimensions in sound shield hxwxd 126x68x80 cm Dimensions without sound shield 115x60x75 cm Colour Metallic silver grey Weight with sound shield 580 kg Weight without sound shield 480 kg Max installation angle 25 degrees Standard supplies Digital remote panel 15 m cable fuel filter fuel lift pump user and installation manuals Available as option Installation kits mobile vehicle version non earth return spare part kits PTO to drive hydraulic pump EN W SQ20 for mobile applications April 2010 15 IS Per Power asta 2 5 15 Electrical diagram control wiring W SQ20 INFORMATION 8 p Jeydeuo ses sue speeds om 104 o u0o euondo aIONTIOs ana some HOLMS HOLIMS vaH3ud MOTO Ss3td TIO aL INVIOOO IWISOWSHL NVS UV 9018 3NION3 2 HOLMS oL oL annoa A Alva ALIVE
28. do service on the vehicle 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 Whisper Power guarantees that this generating set has been built according to good workmanship according to the specifications 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 well 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 and 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 does not cover failures that are caused by misuse neglect or a faulty installation Example 1 Faulty installation Overheating of the engine or alternator is the most common cause of problems with mobile generating sets These problems are caused by poor circulation of the cooling liquid due to wrong routing of the pipes to the radiator bents will capture air bubbles causing air lockes blocking the circulation of the liquid Other examples of installation p
29. e T D C of cylinder 4 and finally to 2 Fig 33 Exploded view soundshield Y 5 4 3 Disassembling instructions It could be necessary for repair or checks to disassemble the generating set Following instructions will help 1 The design of the W SQ20 makes it possible to do most repairs on the spot The connections of the alternator are very accessible The same is true for the diode of the rotor 2 The sound shield canopy can be disassembled according to exploded view below figure 33 36 April 2010 W SQ20 for mobile applications EN amp whisper 3 T TROUBLE SHOOTING Y 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 The easiest way to get the generator out of its capsule is by lifting the set with the aid of the lifting eyes Taking the generator set from its mounting or to replace a mounting can be done according to the drawing below figure 34 U I Fig 34 Exploded view rubber mountings EN W SQ20 for mobile applications April 2010 One can take off the complete alternator housing Before the alternator can be taken off all cables and wiring has to be taken loose first Reassembling the generating set one should take care of alignment cleaning the surfaces between engine and alter
30. e 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 13 INFORMATION 4 whisper Power 2 5 8 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 lf necessary an optional longer 8 wire communication cable can be connected 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 9 Hour counter The remote control offers several timer functions that helps to schedule maintenance 2 5 10 Load indicator On the remote control the load will be indicated on the display and by the LED bar The load is measured by current transformers on the alternator All phases are monitored and overload of all phases or just one or two phases will provoke an alarm or even shut down when the alarm is ignored 2 5 11 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 12 Oil information 1 Spe
31. early 25 MAINTENANCE 4 whisper Power 4 3 1 Maintenance schedule Check oil level daily Check the level of the cooling liquid daily Hoses for loose connections or deterioration daily Change oil and oil filter Check and tighten nuts bolts etc after first 50 hours after first 50 hours Check exhaust 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 and readjust V belt 150 hours Retighten cylinderhead bolts and a readjust valve clearance fter first 300 hours Check impeller engine coolant pump 300 hours Replace oil filter 300 hours Replace fuel filter 300 hours Check the air cleaner element 500 hours Replace the V belt 1000 hours Retighten cylinderhead bolts and readjust 1000 hours valve clearance Check and clean radiators 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air cleaner element 2000 hours Y 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 1 Clean the engine 2 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 3 Drain the ho
32. element 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 e Continuous running with very low load Increase load up to 70 of nominal power and have the engine run for a few hours Loss of power e 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 e Overfull oil sump Bring the oil to the correct level e Choked fuel filter e Choked air cleaner element Replace the fuel filter Check air inlet openings clean air cleaner element e Exhaust blocked Check the exhaust system e Faulty fuel pump Check and replace if nescessary e Injector blocked Have the injector checked e Loss of compression sticking or damaged piston ring e Wear out of cylinder Have the compression measured Clean or replace the rings Have the compression measured and have the engine overhauled Over temperature e Overload e Low level of coolant or air in the cooling system
33. ent figure 25 strongly depends on environmental conditions Check the condition of the element at least every 500 running hours but should be at least every six months TT d Mi ul Mt DAP en Fig 25 Air cleaner element 24 April 2010 W SQ20 for mobile applications EN 5 whisper Power MAINTENANCE Y 4 3 REGULAR MAINTENANCE CHECK DAILY e Oil level see fig 26 Take care the oil level is never below the mark Do not add oil when the level is still above the mark 1 Minimum oil level 2 Maximum oil level Fig 26 CHECK DAILY e Level cooling liquid e Hoses for loose connections or deterioration AFTER FIRST 50 HOURS e Change oil and replace the oil filter Have the engine run until it is on temperature and stop it Replace the oil filter 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 e Check and tighten nuts bolts and unions paying particular attention to the fuel system e 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 e Check and readjust V belt e Check the electrical connections
34. ernal causes e Faulty fuse of the AVR Check fuse of the AVR e Loss of residual magnetism Check the residual magnetism temporally increase RPM with 1596 Try to and flash the alternator see special procedures e Low engine RPM Check the engine RPM and adjust refer to special procedures e Faulty RPM Check by independent excitation if the problem is in the AVR or in the windings and replace if necessary see special procedures e Rotor diode broken Check the diode in the rotor see special procedures The W SQ20 has one diode block rectifier unit Generator output voltage too low when no load is on it less e Engine is not reaching the rated RPM See special procedures to readjust RPM EN W SQ20 for mobile applications April 2010 27 TROUBLE SHOOTING 4 whisper Power PROBLEM CAUSE Y SOLUTION than 225V between phase and neutral e Faulty AVR When slightly too low adjustment could be necessary Try to readjust AVR Check by independent excitation if the problem is in the AVR or in the windings and replace AVR if necessary see special procedures e Defective diode Check the diode in the rotor see special procedures The W SQ20 has one diode block rectifier unit Generator output voltage too low under load less than 225V In no load condition it is OK e When applying 3 phase an unbalanced load check the voltage of the o
35. f no Mass Systemswitch is used Switch main Power Source Selector switch to OFF or switch off all devices 5 Switch on the battery switch Co Starting the generator By pushing the start button briefly the electric system is activated 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 A restart protection prevents starting the engine when it is already running which could cause damage Checks once the generator is in operation 1 Check for abnormal noise or vibration 2 Check the voltage 3 Power source selector switch off external power generator power Switch to power source generator If a Mass System switch is installed this operates automatically 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 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 ro
36. hisper x s CHU identification plate are also some basic features of the set 2 POWER The identification plate gives 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 25 C For higher temperatures the generating set has to be derated To drive the radiator fan 230 V fan output could be taken from power generated by the genset In that case net power will be less than specified on the identification plate YEAR OF MANUFACTURING 3 VOLTAGE shows the nominal voltage Marsifacturer Whisper Power BV This voltage should be within the specified tolerance ta E C at the nominal frequency The W SQ20 can be connected for different voltages in single phase or tri phase The nameplate indicates the connection as made in the factory BE AWARE THAT THE CONNECTIONS COULD BE RECONNECTED BY FORMER USERS 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 1500 rpm 5 CURRENT This shows the maximum current that is acceptable at the specified frequency voltage and power factor When connected in tri phase the indicated current is the current between two phases that can be taken off three times 6 WEIGHT shows the net dry weigh
37. ing off the backend of the alternator Fig 29 Location rectifier diode block 5 3 4 Winding resistant values If after establishing and correcting any fault on the AVR and diodes and output is still low when separately excited then the main rotor stator auxiliary and exciter stator winding resistance should be checked 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 10 of the values given in the table below Resistance W SQ20 e Resistance main stator windings 0 33 Ohm e Resistance rotor windings 1 18 Ohm e Resistance auxiliary winding 3 85 Ohm e Resistance exciter stator winding 18 Ohm e Resistance exciter rotor winding 0 18 Ohm 5 3 5 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 The AVR 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 2 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 60 80 C from a fan heater or similar apparatus into the gene
38. ivnolIdO GwNoIdo pu O F 1 i 1 1 i 1 1 1 i 1 1 1 1 d 1 Uo 9 D SEXDVIE Al did t VON 8 2 d 1 ga 1 A 1 ET 1 T NV uly XOBNOLLONAP 1 1 VNOIO ls i El ln 1 E 1 E 1 g f a5 1 1 A E TT VO L Tava E 5 i E e sg 3 8 z E L E VANIOISNVEL li s E E aurea INIVUND z Ii S Z UIALOSSNVEL 3 In 3 o ONIINSIN INZUINO riekt g o ONIINSIN INZANO BE S E E f TANYA TOULNOD a e B L z 2 E E E amp E 3 3 Bg E S O NN cen sepa post m E y TUN zana zl Ez sl all ls gs TUOMAS ILS WIN 5 E i e alla 2 SI 35 i omron alr oae T anno ant vols MOB S ge dde O ves 290 E E al E is fOHWOD 85810 PUKA xw BI ann a E TOONBISVW O O TANVd TO INOO 1v2O1 gt gt gt n n 2 o S 4 EJ Lov CEUNWOUS EJ vov
39. l 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 3 Switch to an other AC power source if available If a Mass Systemswitch is installed this is done automatically 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 the installation conforms to the installation instructions 3 Ensure the generating set is free to turn without 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 al 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 21 OPERATION 4 whisper Power 2 Check coolant in the expansion tank Check for leakages 4 I
40. l gasket kit Seal kit 50208030 Cylinder head gasket kit 50206040 Glow plug 4pcs 50208050 Nozzle injector 4pcs 50206045 Thermostat 50206038 Gasket thermostat 50208034 Gasket rocker cover More extensive parts list on the internet WHISPERPOWER EU fast moving parts 38 April 2010 W SQ20 for mobile applications EN 4 whisper Power MAINTENANCE LOG Y MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter EN W SQ20 for mobile applications April 2010 39 whisper UI Y Y Kelvinlaan 82 9207 JB Drachten The Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl
41. mes or other sources of ignition around batteries e Keep a fire extinguisher on hand BREAK HERE FIRE EXTINGUISHER PORT IN CASE OF FIRE DO NOT OPEN SOUNDSHIELD TO AVAD SERIOUS INJURY OR DEATH FROM FIRE SHUT DOWN ENGINES GENERATOR SETS AND BLOWERS IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS PORTABLE HRE EXTINGUISHER THROUGH THIS PORT Fig 3 Fire extinguisher port e In case of fire do not open the soundshield To avoid serious injury or death from fire shut down engines generator sets and blowers Break through the label which is indicated by BREAK THROUGH HERE and then immediately discharge entire contents of gaseous portable fire extinguisher through the fire extinguisher port On the generating set this fire extinguisher port is indicated by the label as shown in figure 3 e Poor electrical connections or using wiring which is not suited for the rated currents can cause overheating and possibly fire 2 1 7 Chemicals e 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 e Gaskets may be manufactured from asbestos Particles of this material should not be inhaled as this may result in fatal diseases e On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter
42. nal moving parts like fans and V belts are covered by the soundshield and therefore the W SQ20 is very safe when the soundshield 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 e Do not 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 e 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 e Avoid refilling the fuel tank while the engine is running When oil or fuel is leaking do not use the generating set e Do not run the engine close to explosives or gasses e Hydrogen gas generated by charging batteries is explosive Ensure for proper ventilation Do not smoke or allow sparks fla
43. nator and tighten the bolts crosswise and gradually Use Loctite 577 to seal the fittings which should first be cleaned and made free of oil and grease Test the generating set first outside its capsule and check very carefully for leakages before putting it back in its enclosure 37 SPARE PARTS LIST G whisper Power 6 SPARE PARTS LIST A complete parts manual in English is available as an option number number 40200187 A work shop manual in English is available as an option number 40200174 We recommend the following spares for service and maintenance Kit A parts for regular maintenance parts marked Kit B parts for maintenance spare parts all parts marked article no 40201560 article no 40201561 ARTICLE NO DESCRIPTION 50206122 Fuel filter 50208120 V belt 40208121 Oil filter 50230007 Air cleaner element 50209145 Measuring coil Wh 20 25 3 pcs 50208010 Rotary diode three phase 50208015 Alternator bearing including O ring 50208020 Voltage regulator 50209104 Local control panel 50209099 Digital Diesel Control Unit 3 phase 50212170 Fuses 10 Amps 50212154 Fuses 3 Amps 50212197 Fuses 32 x 6 3 2 Amps 50201559 Wiring loom complete 50209102 Digital Diesel Remote control panel 130010915 Cable remote control 15 mtr including connectors 50208033 Overhau
44. nual priming Fuel injection pump Temperature switch Hoist eye front Alternator Exhaust manifold watercooled Hoist eye alternator Digital Diesel Control DDC Expansion tank Power take off hydro pump Remote control AC power output Coolant injection bend Engine oil pressure switch Starter motor solenoid Starter motor Engine serial number above starter motor solenoid Automatic voltage regulator AVR 11 amp whisper INFORMATION 5 y 2 4 2 Generator control panel 2 5 TECHNICAL INFORMATION 2 5 1 AC alternator Start Stop The tri phase synchronous alternator is directly coupled hen ion one bearing brushless rotating field design 12 wire four Fuse 3A Fuse 3A pole 1500 RPM and regulated by an Automatic Voltage Remove fuse before maintenance Regulator AVR The exciter stator has a residual magnetism which guarantees self exciting of the generator on start up that ed EMI thereby generates a residual voltage of about 10 Whisper Digital Diesel Operation Unit i prepa lia nominal voltage l Replace fuses with same type and rating The AVR powered by an auxiliary circuit on the main iin stator acts on the exciter stator indirectly controlling the field generated by the main rotor by means of the sequence exciter rotor diode bridge main rotor The voltage regulator controls and keeps constant the average voltage of one phase
45. oad 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 coolant 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 Switch to an other 230V 400V power source if available If a Mass System switch 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 April 2010 W SQ20 for mobile applications EN 5 whisper Power MAINTENANCE Y 4 MAINTENANCE 4 1 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 in
46. ock which will result in severe personal injury or loss of life Circumstances could make it also necessary to take additional measures Be aware of wet conditions and hazardous environments caused by explosive gases etc 2 1 2 Electrical safety This warning sign indicates parts which could AN be live The voltage of 230V or 230V 400V 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 Realise that people are not used to have A 230V 400V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance personal of garages that do service on the vehicle 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 EN W SQ20 for mobile applications April 2010 e Using the auto start stop interval mode the generator can start unexpectedly When working on the electrical system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery
47. ome consumers e Defective generator windings Generator must be sent to manufacturer for repair bearings or other of damaged bearing or winding e Damaged engine Repair by Whisper Power 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 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 incomplete combustion caused by Overload choked air cleaner element 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 e Protection system stops the engine this can be caused by oil pressure failure lack of cooling water Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure 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 Engine stops by itself e Overload or short circuit Switch off the consumers and test for short circuit
48. ove 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 31 Tightening torque cylinder head bolt 118 5 Nm Rocker stay tightening torque 10 20 Nm No of bolts 17 Fig 31 Cilinderhead bolt tension sequence The clearance of both intake and exhaust valves should be 0 25 mm in cold condition Set the piston of the first cylinder to be adjusted to top dead centre T D C of compression stroke The T D C of compression stroke can be found by aligning the T D C mark O on the crankshaft pulley with the mark on the gear case 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 Fig 32 Checking valve clearance turning 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 35 TROUBLE SHOOTING amp whisper Power 360 in the direction of engine rotation again No 1 piston is now at T D C of the compression stroke After adjusting the valves of cylinder 1 adjust the valve clearance of the remaining cylinders in firing order 1 3 4 2 Turn the crankshaft 180 clockwise from the T D C of cylinder 1 to the T D C of cylinder 3 Adjusts the valves of cylinder 3 and turn the crankshaft further clockwise to th
49. rator air inlets or outlets 34 April 2010 W SQ20 for mobile applications EN amp whisper Power TROUBLE SHOOTING Y 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 Before readjustment check any other explanation for the wrong speed Engine speed is set at the factory at nominal 1500 50 Hz RPM A RPM drop of 5 at full load is acceptable Therefore a no load setting should be at 1575 RPM 52 5 Hz Under no circumstances should the RPM be under full load below 1470 RPM 49 Hz When no cause can be found for a wrong speed the setting can be adjusted 01 Engine speed adjusting screw Fig 30 Location engine speed adjustment screw It is very important to identify the correct setting assembly see fig 30 The screw is to be locked in position with the lock nut EN W SQ20 for mobile applications April 2010 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts Both procedures have to be executed with a cold engine When both procedures are executed 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 coolant drain plug ref to fig 4 Loosen the bolts slightly rem
50. roblems are hot air circulation into the radiator April 2010 W SQ20 for mobile applications EN E whisper Power INTRODUCTION Y and the radiator fan sucking exhaust gasses into the radiators The generator and other parts should be protected against the influences of the weather and splashing water with dirt and salt below the vehicle 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 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 guarantee Example 3 Neglect Whisper generators have an option for an auto start stop mode or interval mode Whisper Power 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 require
51. s daily use 21 3 2 2 Extended operating instructions eee eee eee eee 21 4 MAIN TENAN O Ei r a di 23 4 1 Alda E A E R 23 4 2 ss lla EE ET T TRT E T T E E TEE 23 4 2 1 Preliminary instructions ea 23 4 2 2 Bleeding fuel les ORO Real ale eite esi ep RU 23 4 2 3 Valve T O ara cp 23 4 2 4 Replacing tuel Mtr ss i oerte tata 24 4 2 5 Replacing oil fiter dms 24 4 2 6 Tensioning belu cd 24 4 2 7 RS vende ee ee Wire ede eed taan ennen aie 24 4 3 Regular maintenance eti as 25 4 3 1 Maintenance schedule eerte enne ela Hn arena ded barber e ZR ETS 26 4 3 2 Putting o t of service nn sereen iicet Aa 26 5 TROUBLE SHOOTING 5 3 o densa deceret eden encre ria II 27 5 1 Alternator electrical faults anneer eneen a nono e non n nn nennen nemen nnnm nennen nnne enn nennen nne nennen 27 5 1 1 General nana A aaa 27 5 1 2 Trouble shooting table alternator sssssseee eene nennen enne enne nnns 27 5 2 Engine faults A e a A o tien 28 5 2 1 General tite agen anai bea suns cnt poder talas podio cei Ret pot deae 28 5 2 2 Trouble shooting table engine cvez des gaead crs 92 cds d oomen Ine ede dne dee nne dae inde rdnr eden 29 5 2 3 Warhings uiic ii rep RUD De DESEE pe io 31 5 2 4 SericeaddresS SSe a a a a td 32 5 3 Special procedures alter ator innne iii EES 33 5 3 1 Automatic Voltage Regulator AVR sse eene nneen nere en rn cr nan nnns 33 5 3 2 Residual voltage check excit
52. s T may arise See par 5 3 1 01 Generator load indicator 02 Failure LED 03 Start button 04 Stop button 05 Display 06 Select button 07 Set button Fig 10 Digital Diesel remote control panel Fig 11 Automatic Voltage Regulator AVR 12 April 2010 W SQ20 for mobile applications EN amp whisper Power INFORMATION Jumper J Fig 12 AVR Trimmers potentiometers The power comes from 12 wires that can be connected in star delta or combined double star and double delta arrangements to take off different voltages For tri phase 400V use the alternator should be connected in star For single voltage 230V use the wires should be connected in double delta The alternator is specially designed that in this way one can take off the full power off the generator However the use of three groups of 230 V taken from the three corners of a single delta arrangement is recommended Other voltages 115 Volt can be arranged as well Further technical data on the connections of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The W SQ20 generating set is based on the Mitsubishi S4S 4 cylinder 4 stroke diesel engine The engine is indirectly injected The engine is water cooled and the cooling liquid is cooled by a radiator The engine has been specially adapted for the Whisper Power application and is very different from the standard engine supplied for industrial applications
53. s for maintenance and spare parts as well as a chapter on maintenance and problem solving All manuals are available on our web site www whisperpower eu INFORMATION 2 4 COMPONENTS 2 4 1 Main components to identify Fig 4 Left View main components W SQ20 Fig 5 Top View main components W SQ20 01 02 03 04 05 06 07 08 09 10 11 12 15 16 17 18 4 whisper Power Thermostat housing Boiler connection Engine coolant pump V belt Exhaust connection Engine coolant OUT Battery Battery Fuel out Fuel in Engine coolant IN Rubber engine mounting Filler cap engine oil Filler cap engine coolant Rubber engine mounting Rocker cover 10 April 2010 W SQ20 for mobile applications EN INFORMATION 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44 45 46 48 49 50 51 52 53 Fig 7 Rear View main components W SQ20 EN W SQ20 for mobile applications April 2010 Hoist eye rear Engine speed adjusting Screw Fuel injector Glowplug 4x Fuel filter Fuses Control panel Air cleaner element Indentification plate Oil sump handpump Coolant drain plug Engine oil dipstick Fuel solenoid Cil filter Injection pump air bleeding Screw Fuel lift pump for ma
54. sulation resistance to earth see section 5 3 5 Meggering The alternator bearing is greased for life and is therefore 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 after 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 DA 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 EN W SQ20 for mobile applications April 2010 4 2 2 Bleeding fuel lines 1 Ensure there is sufficient fuel in the fueltank 2 Loosen the air bleeding screw 1 1 5 turns See Fig 20 3 Unlock lift pump plunger 2 See fig 20 by turning it to the left 4 Operate the lift pump by hand moving the lift pump plunger up and down till fuel flows out free of air bubbles 5 Lock lift pump plunger 2 See fig 16 by pushing it full down and turning it to the right 6 Tighten the air bleeding screw 1 Fig 20 Bleeding fuel lines 1 Air bleeding screw
55. t approximately in kg This is without fuel oil cooling liquid packing and external installation equipment 7 CE marking the CE symbol shows that the generating set is build according to European Community safety regulations This includes the regulations regarding safety of machinery electric safety and electric magnetic compatibility EMC and other relevant directives NO pra ATT n 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 not 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 Fig 2 Location identification plate 6 April 2010 W SQ20 for mobile applications EN E whisper Power INFORMATION Y 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 DANGER A Warning signs draw attention to special warnings instructions or procedures which if not strictly observed may result in electrical sh
56. t engine oil and refill with preservation oil 4 Stop the engine 5 The 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 April 2010 W SQ20 for mobile applications EN E whisper Power TROUBLE SHOOTING Y 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 Failure code Problem If during these measurements the engine immediately stops after starting and an error code is displayed at the remote control panel AC VOLTAGE one can start the generator by means of a service start a
57. t the service menu see paragraph service start of the user s 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 carry out measurements to investigate the cause of the failure Check if the engine is running correctly at 1500 RPM 50 Hz according to its settings and does as well under load A RPM drop of 5 at full load is acceptable Therefore a no load setting should be at 1575 RPM 52 5 Hz Under no circumstances should the RPM under full load be below 1470 RPM 49 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 AC ALTERN TEMP AC alternator 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 1 2 Trouble shooting table alternator PROBLEM CAUSE SOLUTION No output Voltage at all e Circuit breaker off or faulty main fuse Check switches and fuses and measure directly on the alternator to exclude ext
58. ther phases When the voltages are different this is caused by an unbalanced load Bring load in balance When slightly out of balance remove the sense wires to the phase with the highest load and check if the voltage on the other phases is not too high e Engine is not reaching the rated RPM Possibly too much load or engine problems lack of fuel Switch off a load part off consumers See to engine RPM problems e Faulty AVR or readjustment necessary Try to readjust the voltage Check by independent excitation if the problem is in the AVR or in the windings and replace AVR if necessary see special procedures Generator output voltage too high more than 235V e Over energising due to defective AVR or wrong AVR setting Check AVR readjust and replace if necessary capacitor specification and replace AVR if necessary see special procedures Generator output voltage too high more than 235V In no load condition it is OK e Unbalanced load Bring load in balance When slightly out of balance remove the sense wires to the phase with the highest load and check if the voltage on the other phases is not too low Generator voltage fluctuates e Disturbances on the electrical system user side e AVR reacts on fluctuating load Check if electrical load is fluctuating Readjust the stability setting on the AVR trimmer ST e Engine runs irregularly When engine runs irregularly see se
59. ugh 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 Y 70 or the rated generating sets maximum load Please note this when switching on your electrical devices Nevertheless the W SQ20 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 generator 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 MA 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 l
60. valid for the following models Part number Description 41101020 W SQ20 230V 1500rpm Mobile keel cooling 41101026 W SQ20 230V 1500rpm Mobile keel cooling ungrounded 41101320 W SQ20 230V 400V 1500rpm Mobile keel cooling 41101326 W SQ20 230V 400V 1500rpm Mobile keel cooling 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 without 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 DANGER Realise that people are not used to have 230V 400V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance personal of garages that

Download Pdf Manuals

Related Search

Related Contents

Voglia di lavorare saltami addosso!  SMP superscalar user`s manual v.2.2  Manual original  HRS 2500 - Service  Painel Plano de 20”    Sistema de Guiado para Peatones, Ciclistas y  

Copyright © All rights reserved. Failed to retrieve file