Whisper Power 41207320 User Manual Download Page 1

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USERS MANUAL FOR MOBILE APPLICATIONS

W-SQ-Pro

15kVA/10.8kW • 18kVA/15.5kW

1500 RPM

Mobile diesel generating set 230/400V-50Hz

Three phase, 5 wire Digital Diesel Control

WHISPERPOWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: +31-512-571550
Fax.: +31-512-571599
www.whisperpower.com

V1 Feb 2020

Summary of Contents for 41207320

Page 1: ...15kVA 10 8kW 18kVA 15 5kW 1500 RPM Mobile diesel generating set 230 400V 50Hz Three phase 5 wire Digital Diesel Control WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com V1 Feb 2020 ...

Page 2: ...mponents to identify 10 2 4 2 Generator control panel 12 2 4 3 Remote control panel 12 2 5 Technical Information 12 2 5 1 AC alternator 12 2 5 2 Engine 13 2 5 3 Digital Diesel Control system 13 2 5 4 Battery charger 13 2 5 5 Alarms and shut down 13 2 5 6 Monitoring 13 2 5 7 Control 13 2 5 8 Remote control 13 2 5 9 Hour counter 13 2 5 10 Load indicator 13 2 5 11 Fuel specification 13 2 5 12 Oil inf...

Page 3: ...r maintenance 28 4 3 1 Maintenance schedule 29 4 3 2 Putting out of service 29 5 TROUBLE SHOOTING 30 5 1 Alternator electrical faults 30 5 1 1 General 30 5 1 2 Trouble shooting table alternator 31 5 2 Engine faults 32 5 2 1 General 32 5 2 2 Trouble shooting table engine 33 5 2 3 Warnings 35 5 2 4 Service address 35 5 3 Special procedures alternator 36 5 3 1 Automatic voltage regulator 36 5 3 2 Res...

Page 4: ...nger 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 230 400 Volt available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance persona...

Page 5: ... example if a 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 areas any additional costs incurred over normal carriage will be invoice...

Page 6: ...cated windings 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 Whisper Power offers generators for 1800 rpm 60 Hz applications as well When necessary a W SQ Pro 15 10 8 Three Phase model can be reconnected and se...

Page 7: ...ion must be done in accordance with local standards 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 Warning signs indicate parts which could be live 2 1 3 Earth insulation failures According to local regulations and dep...

Page 8: ... 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 Fig 2 Fire extinguisher port In case of fire do not open the soundshield To avoid serious injury or death from fire shut down engines generator set...

Page 9: ...hile the battery is stored it should be recharged every 12 weeks 2 3 THE W SQ PRO 15 10 8 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 ...

Page 10: ...ront left view main components W SQ Pro 15 10 8 _ 18 15 5 three phase mobile Fig 4 Front right view main components W SQ Pro 15 10 8 _ 18 15 5 three phase mobile 01 Remote control cable 02 AC power output 03 Battery cable 04 08 09 Battery cable Fuel injector Accelerator 10 Fuel out 11 Fuel in 12 Oil filter 13 Heat sensor ...

Page 11: ...w main components W SQ Pro 15 10 8 _ 18 15 5 three phase mobile Fig 6 Rear view main components W SQ Pro 15 10 8 _ 18 15 5 three phase mobile 16 Raw water pump 17 Rubber engine mounting 18 Filler neck 19 Filler cap engine oil 20 Thermostat cover 21 Coolant water pump 22 V belt 23 Dynamo 24 Starter motor 25 Manifold ...

Page 12: ...elp of a trimmer V 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 regulatin...

Page 13: ...lay and the engine will be shut down There are three functions guarded oil pressure coolant temperature and alternator temperature Too high alternator temperature indicates the alternator coolant to be blocked or the pump impeller to be damaged 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 th...

Page 14: ...onents 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 ag...

Page 15: ...tput voltage 230 400V 50 Hz alternating current AC three phase re connectable to three phase 230V Output rating 12 kVA 12kW at power factor cos phi 1 Voltage tolerance 2 balanced load Frequency tolerance 1 electronic governor Alternator Air cooled brushless four pole 6 or 12 wire synchronous Voltage regulation AVR MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on ru...

Page 16: ...mm2 DDC fuel solenoid hold 9 green 1 5 mm2 DDC fuel solenoid pull 20 pink 1 5 mm2 DDC fuel solenoid com 17 black 1 5 mm2 B terminal alternator starter motor 21 red 6 mm2 DDC R terminal alternator 18 white 1 5 mm2 DDC L terminal alternator 19 orange 1 5 mm2 DDC current measuring transformer AC1 66 black 1 mm2 DDC current measuring transformer AC1 66 red 1 mm2 DDC current measuring transformer AC2 7...

Page 17: ... 8 W SQ Pro 18 15 5 Three phase for mobile applications February 2020 17 2 5 16 Lay out control wiring Fig 12 Electrical Diagram control wiring W SQ12 three phase mobile applications See figure 15 for connection of the radiator fan ...

Page 18: ...INTRODUCTION 18 February 2020 W SQ Pro 15 10 8 W SQ Pro 18 15 5 ...

Page 19: ... Three phase for mobile applications February 2020 19 2 5 17 Electrical diagrams AC connections alternator models with 6 wires Only valid for alternator models with 6 wires Fig 13a Electrical Diagram 230 400 V AC 50 Hz three phase Star configuration ...

Page 20: ...INTRODUCTION 20 February 2020 W SQ Pro 15 10 8 W SQ Pro 18 15 5 Only valid for alternator models with 6 wires Fig 13b Electrical Diagram 230 400 V AC 50 Hz three phase Delta configuration ...

Page 21: ...Three phase for mobile applications February 2020 21 2 5 19 Electrical diagrams AC connections alternator models with 12 wires Only valid for alternator models with 12 wires Fig 14a Electrical Diagram 230 400 V AC 50 Hz three phase Star configuration ...

Page 22: ...INTRODUCTION 22 February 2020 W SQ Pro 15 10 8 W SQ Pro 18 15 5 Only valid for alternator models with 12 wires Fig 14b Optional configuration modes of the AC wiring for alternator models with 12 wires ...

Page 23: ...SQ Pro 15 10 8 W SQ Pro 18 15 5 Three phase for mobile applications February 2020 23 2 5 20 Electrical diagrams radiator fan connection Fig 15 Electrical diagram for standard fan control using a 230 Volt AC radiator fan ...

Page 24: ... So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the fuel pump without levers and o...

Page 25: ...mmarised operating instructions daily use Routine pre start checks 1 Check oil level refer to fig 17 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 valv...

Page 26: ...utomatically 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 5 Check all cables and cable end term...

Page 27: ...ces 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 W SQ12 is designed so as not to overheat even under...

Page 28: ...he fuel system 4 2 2 Bleeding fuel lines 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 1 Ensure there is sufficient fuel 2 Release the fuel bleed screw 1 See fig 18 3 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...

Page 29: ...mm refer to fig 21 4 2 7 Air filter element The interval for cleaning of the air filter element figure 22 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 Fig 22 Air filter element 4 2 8 Air strainer element The W SQ12 for mobile applications is standard supplied with an air strainer element fig...

Page 30: ...own Check and readjust V belt Check the electrical connections EVERY 150 HOURS Change oil Check the battery acid level not applicable when Whisper Power batteries are used Check battery terminals for corrosion Check and readjust V belt EVERY 300 HOURS Replace the oil filter Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 hours Isolate the...

Page 31: ...ours Check and clean radiators 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air filter element 2000 hours 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 p...

Page 32: ...a service start at 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 If the bottom speed is set at too low a frequency the generator may be damaged On the other hand too high a fre...

Page 33: ...es 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 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 Fa...

Page 34: ...om 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 Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low AL...

Page 35: ...k wire connections and circuitry to solenoid Refer to DC wiring diagram Fuel lift pump is not working Fuel filter is blocked 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 Wrong valve clearance Adjust valve clearance Low compression because of dirty valves Clean valves Take off the injection bent and insp...

Page 36: ...mperature too high unsuitable fuel or water in fuel Check the fuel Check for overload Check the air intake Engine starts but stops after 10 up to 30 seconds 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 informat...

Page 37: ...place the fuel filter Choked air filter element Check air inlet openings clean or replace air filter element Exhaust blocked Check the exhaust system Faulty fuel pump Check and replace if necessary Injector blocked Have the injector checked Loss of compression sticking or damaged piston ring Have the compression measured Clean or replace the rings Wear out of cylinder Have the compression measured...

Page 38: ...ed and turn until the required voltage is obtained Fig 25 Automatic Voltage Regulator AVR 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...

Page 39: ...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 Alternator models with 6 wires Resistance main stator windings 0 39 Ohm Resistance rotor windings 2 4 Ohm Resistance auxiliary winding 7 5 Ohm Resistance exciter stator wi...

Page 40: ...orque 14 7 2Nm Fig 28 Cylinder head bolts 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 notch on the crankshaft pulley with the mark on the gear case ref to fig 29 First align the T D C mark ...

Page 41: ... to get the generator out of its capsule is by lifting the set with the aid of the lifting eyes 4 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 5 The rotor can be taken off by removing the bold which goes through the shaft normal clockwise threaded The end of the shaft is specially threaded to push off the ...

Page 42: ...1 Oil filter 50209132 Measuring coil 3 pieces 50212902 Rotary diode assembly three phase 50212901 Voltage regulator 50209104 Local control panel 40209099 Digital Diesel Control Unit three phases 50212154 Fuse blade type 3 Amp 32V violet 50212170 Fuse blade type 10 Amp 32V red 50212198 Fuses 20 x 5 3 15 Amps 50201366 Wiring loom complete 40209102 Digital Diesel Remote control panel 50209133 Cable r...

Page 43: ...E LOG EN W SQ Pro 15 10 8 W SQ Pro 18 15 5 Three phase for mobile applications February 2020 43 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Page 44: ...NOTES 44 February 2020 W SQ Pro 15 10 8 W SQ Pro 18 15 5 NOTES ...

Page 45: ...NOTES EN W SQ Pro 15 10 8 W SQ Pro 18 15 5 Three phase for mobile applications February 2020 45 NOTES ...

Page 46: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com sales whisperpower com ...

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