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INSTALLATION

W-GV/2, W-GV/3, W-GV 8 and W-GV 10 —

March

2015 — EN

5

2

INSTALLATION

2.1

GENERAL

To ensure reliability and durability of the equipment, it is very
important  that  the  installation  is  carried  out  with  the  utmost
care  and  attention. To  avoid  problems,  such  as  temperature
problems, noise levels, vibration, etc. the instructions set out in
this manual must be followed and all installation work must be
carried out professionally.

2.2

LOCATION

When looking for a proper place for a genverter in a vehicle all
relevant aspects have to be taken into account

Accessibility

Solid foundation

Space to mount the radiator (refer to 2.8)

Space to mount the exhaust (refer to 2.9)

A route to fit the fuel lines

The air flow through the genset (refer to 2.6)

Because  of  their small dimensions, WhisperPower genverters
can  be  installed  in  tight  locations. Please  consider  that  even
almost  maintenance-free  machinery  must  still  remain
accessible.
When selecting the location for the genverter, make sure there
is sufficient room to carry out any maintenance work. The unit
must  be  easily  accessible  on  the  service  side.
All models can be serviced from one side. Oil filling can be done
on  the  service  side  and  on  the  top. The  top  of  the  engine
(rocker cover) has to be accessible for adjustment of the valve
clearance.
Please  also  note  that  in  spite  of  the  automatic  oil  pressure
switch the oil level must checked regularly.

2.3

PROTECTION AGAINST  DIRT,  SAND  AND  BAD

WEATHER CONDITIONS

The unit can be mounted below a vehicle. However, be aware
of  the  bad  conditions  below  a  truck when  driving  in  rain  or
snow. Also protect the unit from a spray of water and/or mud
behind the wheels. In some territories there is sand in the air.
In such situations, it is recommended to fit the air inlet of the
engine compartment with an air inlet strainer.

Figure  5:  Mounting  of  the WhisperPower genverter.
X = wrong, V = OK

2.4

SOUND AND VIBRATION REDUCTION

Position  the genverter as  low  as  possible  in  the vehicle. The
genverter is  secured to  the  base  frame inside  the  canopy by
means  of a  double flexible  engine  mountings system. This
frame is must  be  solidly mounted in  the  vehicle,  not  using
rubber mountings again. When it is possible to mount the unit
directly  on  the  chassis  of  the  vehicle this  has  advantages  in
preventing vibrations by resonance.

2.4.1

Further recommendations

WhisperPower genverters are standard equipped with a sound
cover  canopy. This  sound  cover  has  been  designed  to  give
effective  sound  insulation. For  optimum  sound  and vibration
dampening, the following factors should be considered.
1

Most importantly, the structure on which the genverter is
placed must be  stiff. Directly  below  the  base  frame, the
structure should be supported vertically to the chassis of
the vehicle. When this is not possible horizontal structures
should be made stiff by additional provisions (Figure 5).

2

In  larger  vehicles  a  separate  and  insulated  space  for  the
genverter will help to dampen the noise even further.

3

Avoid  mounting  the genverter in  close  proximity  to  thin
walls or floors that may cause resonance.

4

Sound  dampening  is  extremely  poor  if  the genverter is
mounted on a light weight flimsy surface such as plywood
which will only amplify vibrations. If mounting on a thinner
surface  cannot  be  avoided,  this  should  be  at  least  be
reinforced  with  stiffening  struts  or  ribbing. If  possible,
holes should be drilled or cut through the surface to help
reduce the resonance. Covering the surrounding walls and
floors  with  a  heavy  coating  plus  foam  will certainly
improve the situation.

5

Never connect the base of the genverter directly to walls
or tanks (Figure 5).

Summary of Contents for W-GV/2

Page 1: ...5 INSTALLATION MANUAL W GV 2 W GV 3 W GV 8 and W GV 10 genverters for mobile use WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com Art...

Page 2: ...8 2 How and where to mount the expansion tank 8 2 9 Dry exhaust system 9 2 9 1 General remarks 9 2 9 2 The standard dry exhaust system 10 2 9 3 Installation of the exhaust 10 3 ELECTRICAL INSTALLATION...

Page 3: ...any inaccuracy or the consequences thereof Keep this manual in a secure place 1 2 VALIDITY OF THIS MANUAL All of the specifications provisions and instructions contained in this manual apply solely to...

Page 4: ...tter be mounted outside the canopy and outside the vehicle This can be in the side below or on top or of the vehicle The exhaust is of the dry type and includes a stainless steel flexible bellow and h...

Page 5: ...situations it is recommended to fit the air inlet of the engine compartment with an air inlet strainer Figure 5 Mounting of the WhisperPower genverter X wrong V OK 2 4 SOUND AND VIBRATION REDUCTION P...

Page 6: ...o circulate fresh air Air outlets should be at the top of the engine compartment to remove the hottest air An engine compartment blower should be used as an extraction ventilator to remove air from th...

Page 7: ...re not acceptable a noiseless pump is available as an option Art no 50202200 Figure 9 Fuel line assemblies with pump mounted vertically or in an angle 2 7 3 Fuel pipes When the tank is above the genve...

Page 8: ...le to build the radiators and shield on a sub frame that is mounted below the vehicle as a module MEASURES HAVE TO BE TAKEN TO PREVENT THE HOT AIR FROM CIRCULATING AND REDUCING THE CAPACITY OF THE RAD...

Page 9: ...e manifold to the expansion tank The cooling system should be filled with long life G12 cooling liquid Initially the engine cooling system can be filled via the cap on the exhaust manifold of the engi...

Page 10: ...nkets for thermal and acoustic insulation The mufflers are high quality industrial mufflers much more effective robust and durable than mufflers made for automotive use 2 9 3 Installation of the exhau...

Page 11: ...ing the modular connectors on the back of the units Actually the slaves are regular remote control panels offering all functions again When using the factory settings installation is very simple just...

Page 12: ...settings other than the factory settings refer to the DDC user s manual especially to the APPENDIX 3 6 STARTER BATTERY For starting the genverter requires a 12V starter battery of at least 55 Ah 80 Ah...

Page 13: ...wer PowerCube or Power Module installed with the genverter Be sure that all electrical installations including all safety systems comply with all regulations required by the local authorities All elec...

Page 14: ...en there is only a circuit breaker use it to disconnect the generating set from the grid 7 Check all DC connections check if the battery switch circuit breaker is closed 8 Open the fuel valve Check if...

Page 15: ...n muffler 6 1 50221421 Union F F 7 1 50230610 Resonance muffler 8 1 50220041 Stainless steel flexible exhaust pipe F M 9 6 50211406 Washer M10 10 6 50211447 Spring washer 11 6 50211466 Nut M10 12 1 50...

Page 16: ...th hose nipple 8 mm TOTAL 40230205 FUEL KIT OPTIONAL MATERIALS AVAILABLE no qty article no description dimensions 48 50221522 Hose clamp stainless 10 16 mm not shown per m 50222020 copper fuel pipe 6x...

Page 17: ...March 2015 EN 17 5 DIAGRAMS DRAWINGS 5 1 SYSTEM DIAGRAMS NOTE A4 size drawings can be downloaded from www whisperpower com Figure 24 Layout of genverter system with PMG Figure 25 Example of marine ge...

Page 18: ...W GV 3 W GV 8 and W GV 10 March 2015 EN 5 2 MECHANICAL DRAWINGS Figure 26 Two cylinder genverter mechanical drawings Figure 27 Three cylinder genverter mechanical drawings 650 600 Service side Footpr...

Page 19: ...and DC belt driven generators Power Conversion Sinewave inverters Inverter chargers Battery chargers Monitoring and control Power Storage AGM and gel batteries Lithium ion batteries Battery related p...

Page 20: ...Ref PM WP GV8 Date 5 8 2016...

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