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Whisper Power W-SQ 16, Installation Manual

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Whisper Power W-SQ 16 Installation Manual Download Page 10

 
 
 
 
 
INSTALLATION

 

 

10

 

December 2016 / W-SQ6/8/12/16 for mobile applications / EN 

 

Figure 9a: W-SQ12 connections 

 

 

Figure 9b: W-SQ12 connections

 

 

05 

Coolant engine out  

06 

Coolant generator out 

07 

Fuel out Ø8mm 

08 

Fuel in Ø8mm 

09 

Battery negative (

–) 

25mm² 

10 

Battery positive (+) 

25mm² 

11 

Coolant generator in 

12 

Coolant engine in 

 

 

 

 

 

01 

Expansion tank Ø8mm 

02 

Exhaust 1½” 

03 

Remote control 

04 

AC power output 

 

 

 

 

 

Summary of Contents for W-SQ 16

Page 1: ...8 12 16 1500 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com V1 1 December 2016 Art nr 40200241 ...

Page 2: ... Volt 23 3 INSTALLATION SPECIFICATIONS 24 3 1 General 24 3 2 Commission table 24 3 3 Technical data 25 3 4 Installation materials 26 4 DIAGRAMS DRAWINGS 33 4 1 Layout generator control for W SQ6 8 and 12 with 230VAC fan 33 4 2 Layout generator control for W SQ6 with 12VDC fan 34 4 3 Layout generator control for W SQ6 with 24VDC fan 35 4 4 Layout generator control for W SQ16 with 230VAC fan 36 4 5 ...

Page 3: ...l result in severe personal injury or loss of life WARNING Before working installation on the system read the section safety instructions in the user s manual 1 2 GENERATING SETS FOR VEHICLES 1 2 1 Marine and mobile generators WhisperPower generators originate from the marine sector But there are also specially designed Whispers available for mobile applications suitable for supplying power on boa...

Page 4: ...nce in the working temperature of engine and alternator it will be clear that it is not possible to combine the cooling of the engine and alternator in one radiator system Furthermore it will be clear that it is very difficult to cool an alternator optimally with the aid of a radiator in conditions with high ambient temperatures 1 2 3 Why the alternator should be liquid cooled For normal industria...

Page 5: ... 2 5 3 A way to fit the fuel lines Since WhisperPower generating sets have extremely compact dimensions they can be installed in tight locations Please consider that even almost maintenance free machinery must still remain accessible When selecting the location area in which to mount the generating set make sure there is sufficient room to carry out any maintenance work The unit must be easily acc...

Page 6: ...will certainly improve the situation 5 Never connect the base of the generating set directly to walls or tanks 2 4 VENTILATION 2 4 1 General The generating set normally draws air from the engine compartment Engine compartment with natural ventilation must have vent openings of adequate size and location to enable the generating set to operate without overheating To allow an ample supply of air wit...

Page 7: ...m hanging down Use sealant or kit between the flange and the surface ATTENTION In any case it is necessary to open a hole for air inlet 2 5 CONNECTIONS The generating set comes with all supply lines and output cables i e electric cables coolant connections exhaust fuel lines etc already connected to the engine and generator The supply lines are fed through the capsule s front base The connections ...

Page 8: ...ns EN Figure 7 W SQ6 connections 01 Coolant generator in 02 Battery positive 03 Fuel out Ø8mm 04 Fuel in Ø8mm 05 Battery negative 06 Coolant engine out 07 Coolant engine in 08 Coolant generator out 10 Expansion tank 11 Exhaust 1 12 AC power output 13 Remote control ...

Page 9: ...connections Figure 8b W SQ8 connections 01 Expansion tank Ø8mm 02 Exhaust 1 03 Remote control 04 AC power output 05 Coolant engine out 06 Coolant generator out 07 Battery negative 25mm 08 Fuel out Ø8mm 09 Fuel in Ø8mm 10 Battery positive 25mm 11 Coolant generator in 12 Coolant engine in ...

Page 10: ... connections Figure 9b W SQ12 connections 05 Coolant engine out 06 Coolant generator out 07 Fuel out Ø8mm 08 Fuel in Ø8mm 09 Battery negative 25mm 10 Battery positive 25mm 11 Coolant generator in 12 Coolant engine in 01 Expansion tank Ø8mm 02 Exhaust 1 03 Remote control 04 AC power output ...

Page 11: ... connections Figure 10b W SQ16 connections 01 Expansion tank Ø8mm 02 Exhaust 1 03 Remote control 04 AC power output 05 Coolant engine out 06 Coolant generator out 07 Coolant generator in 08 Coolant engine in 09 Fuel in Ø8mm 10 Fuel out Ø8mm 11 Battery positive 35mm 12 Battery negative 35mm ...

Page 12: ...o the lines of the vehicles engine fuel supply Driving the tank empty below the level of the suction pipe of the generator could make it necessary to bleed the fuel system 2 FUEL LIFT PUMP The generating set itself is equipped with a fuel lift pump therefore the tank can be installed at a lower level than the generating set See figure 12 The maximum suction height is 1 m The W SQ16 has a mechanica...

Page 13: ...Fig 12 Fuel supply fuel tank is below the generating set 1 Fuel return 2 Fuel supply 3 Prefilter Water separator optional 4 Extra fuel lift pump optional 5 Fuel tank Figure 13 Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle A 1 3 2 5 4 ...

Page 14: ...crease the pressure 4 FUEL FILTERS A fine fuel filter is installed which requires maintenance WhisperPower advises to install an extra fuel filter water fuel separator near the fuel tank Before starting your generating set for the first time follow the fuel system bleeding procedure in the user s manual 2 5 2 Radiator cooling 2 5 2 1 TopCool radiator system Where a roof mounted cooling system is c...

Page 15: ...used to drain redundant liquid that is thrown out because of the expansion of the liquid in the system When open the expansion tank can easily release air that is ventilated by the different connections As the capacity of the alternator cooling system is very small also the initial filling can be done via the expansion tank It could be necessary to refill the tank a few times The pump of the alter...

Page 16: ...nected to the expansion tank Also when the radiator is mounted flat at the bottom of the vehicle the outgoing connection is connected to the expansion tank This is the best way to have the system release air and to add liquid when necessary The expansion tank must be fitted in the outlet of the radiator the inlet pipe of the engine Figure 20 Outgoing connection connected to the expansion tank When...

Page 17: ... distance between the radiator and the shield should be at least 50 mm Sometimes it is possible 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 circulating and reducing the capacity of the radiators Refer to figure 23 Figure 23 Bottom mounted radiators with shield Figure 24 Making use of the space below...

Page 18: ...and run at low speed In this mode they almost produce no noise Only when necessary this is controlled by thermostat switches the fans are switched in parallel and will blow at full speed The same is achieved with 230 V fans with help of a transformer refer to the connection diagrams in paragraph 4 8 However when not strictly necessary we recommend using the standard fan control instead of the two ...

Page 19: ...n find space below the vehicle between the chassis to mount the mufflers The outlet should blow the fumes away from the doors to avoid a nasty smell When the gasses are in the flow of air blowing from the radiators this will help to avoid the fumes to be noticed Under no condition the fumes should be sucked into the flow of air into the radiators In wind still conditions a light smell of exhaust f...

Page 20: ... using the plastic cover Refer to the dimensional drawings in chapter 4 More remote control panels slave panels can be put in parallel by using the modular connectors on the back of the units As a slave one can use the same panel offering all functions again It is also possible to use an old or new type slave panel only to start and stop the generator Old type remote panels and system panels can b...

Page 21: ...be connected directly on the second battery before a main switch and be protected by a 3 Amps fuse Monitoring the generator starter battery does not require an extra sense connection Settings When one want to apply other settings than the factory settings refer to the DDC user s manual especially to the APPENDIX 2 STARTER BATTERY For starting the engine requires a 12V starter battery with the foll...

Page 22: ...tra heavy battery charger a 230 Volt fan on the radiator is recommended One should realize that the power for the fan must be decucted from the output power of the generating set 4 OTHER RECOMMENDATIONS AND WARNINGS The battery should be secured for poor road conditions and the terminals should be insulated For extra safety the battery can be enclosed in a wooden plastic fiberglas etc non metal bo...

Page 23: ...the system a motor protection switch must be installed 2 GROUNDING The AC alternator windings are not grounded The housing of the alternator and all other metal parts are grounded To make a connection between neutral and ground is necessary as part of a specific insulation failure protection system It is possible that the electric installation in the vehicle must be protected against insulation fa...

Page 24: ... the grounding 7 Check if an AC breaker is installed before or after the power source selector When there is only a circuit breaker use it to disconnect the generating set from the grid 8 Check all DC connections check if the battery switch circuit breaker is closed 9 Open the fuel valve Check if there are no air leaks in the fuel supply line and check if the lift of the fuel is less than 1 meter ...

Page 25: ...arger alternator including regulator 40 Amps 50 Amps Note that this value must be reduced by the power to drive the cooling fans of the radiators W SQ12 AND W SQ16 Model W SQ12 W SQ16 Dimensions l x w x h 106 x 58 x 63 cm 116 x 58 x 70 cm Weight including sound shield 380 kg 440kg Max operation angle 25 25 Remote panel 15 m cable Digital Diesel Control System Battery capacity min 12V 70Ah 12V 120A...

Page 26: ... mm 45 2 50221620 Hose connection outer cone M16 1 5 mm 8 mm 46 40230092 Filter for fuel strainer water separator 48 4 50221522 Hose clamp stainless 10 16 mm 49 2 50221632 Gasket ring 18 14 1 5 mm not shown 2 50221203 Straight coupling 8 mm not shown 2 50221252 Barbed smooth hose nipple 8 mm TOTAL 40230205 FUEL KIT OPTIONAL INSTALLATION MATERIALS no qty article no description dimensions 48 1 50221...

Page 27: ...ON KIT FOR BATTERIES UP TO 100 Ah RECOMMENDED BATTERY article no description dimensions 40290061 AGM Power 12V 80Ah Absorbed Glass Matt 350 167 180 mm BATTERY INSTALLATION KIT W SQ16 article no description dimensions 61112007 WBC Handy 70 charger 12V 7A 225 50 50 mm 40290093 battery terminal NEG 40290094 battery terminal POS 40290099 M8 battery pole adapter set 40290098 isolation caps red black 50...

Page 28: ... 50230304 Radiator cooler AP 300 2 E 230VAC 32 2 50221103 Straight reducer m f 1 3 4 33 1 50221063 Male nipple 3 4 34 1 50221043 TEE fittings 3 4 35 3 50221004 Male hose connection 3 4x20 38 1 50212405 Temperature switch 35 45 C 39 4 50201121 Vibration mounting 30x25 40 4 50211152 Bolt hexagonal ZP M8x16 41 8 50211465 Nut hexagonal ZP M8 42 8 50211405 Washer ZP M8 43 8 50211445 Washer spring ZP M8...

Page 29: ...INSTALLATION SPECIFICATIONS EN W SQ6 8 12 16 for mobile applications December 2016 29 Figure 34 Engine cooling kit exhaust kit and alternator cooling kit ...

Page 30: ...531 Expansion tank 20 mm TOTAL 40201888 Radiator cooling kit alternator 230VAC W SQ16 RADIATOR COOLING KIT ENGINE 230VAC W SQ6 see 2 5 2 1 for TopCool alternative no qty article no description 1 1 50230304 Radiator cooler AP 300 2 E 230VAC 2 2 50221502 Hose clamp stainless19 29 3 1 50221064 Male nipple 1 4 1 50221044 TEE fitting 1 5 2 50221010 Male hose connection 1x25 6 1 50221103 Straight reduce...

Page 31: ...ainless19 29 3 1 50221064 Male nipple 1 4 1 50221044 T stuk 1 5 2 50221014 Male hose connection 1x35 6 1 50221103 Straight reducer m f 1 3 4 7 1 50221004 Male hose connection 3 4x20 8 1 50212409 Temperature switch 87 82 C 9 4 50201121 Vibration mounting 30x25 10 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexagonal ZP M8 12 4 50211405 Washer ZP M8 13 8 50211445 Washer spring ZP M8 14 6m 5...

Page 32: ... 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexagonal ZP M8 12 4 50211405 Washer ZP M8 13 8 50211445 Washer spring ZP M8 14 6m 50220013 Cooling water hose smooth 1 32x45mm 15 4 50221504 Hose clamp stainless 38 50 16 8 50221597 Hose support ZP 45x25 mm galvanised 17 1 50230529 Bracket expansion tank for 50230531 17 1 50230531 Expansion tank 20 mm 17 1 50230532 Cap tank 0502 30531 18 1 5m ...

Page 33: ...le applications December 2016 33 4 DIAGRAMS DRAWINGS 4 1 LAYOUT GENERATOR CONTROL FOR W SQ6 8 AND 12 WITH 230VAC FAN Fig 35 Layout generator control for W SQ6 8 and 12 with 230VAC radiator fan Optional control for two speeds fans See chapter 4 8 ...

Page 34: ...cember 2016 W SQ6 8 12 16 for mobile applications EN 4 2 LAYOUT GENERATOR CONTROL FOR W SQ6 WITH 12VDC FAN Fig 36 Layout generator control for W SQ6 with 12VDC radiator fan Optional control for two speeds fans See chapter 4 9 ...

Page 35: ...SQ6 8 12 16 for mobile applications December 2016 35 4 3 LAYOUT GENERATOR CONTROL FOR W SQ6 WITH 24VDC FAN Fig 37 Layout generator control for W SQ6 with 24VDC radiator fan Optional control for two speeds fans See chapter 4 9 ...

Page 36: ...mber 2016 W SQ6 8 12 16 for mobile applications EN 4 4 LAYOUT GENERATOR CONTROL FOR W SQ16 WITH 230VAC FAN Fig 38 Layout generator control for W SQ16 with 230VAC radiator fan Optional control for two speeds fans See chapter 4 8 ...

Page 37: ...pressure switch 6 purple black 1 mm DDC water temperature switch 7 blue 1 mm LCP water temperature switch 7 blue black 1 mm DDC exhaust temperature switch 8 blue green 1 mm LCP exhaust temperature switch 8 blue rose 1 mm DDC fuel solenoid hold 9 green 1 5 mm DDC fuel solenoid pull 20 pink 1 5 mm DDC fuel solenoid com 17 black 1 5 mm B terminal alternator starter motor 21 red 6 mm DDC R terminal al...

Page 38: ...blue 1 mm LCP water temperature switch 7 blue black 1 mm DDC exhaust temperature switch 8 blue green 1 mm LCP exhaust temperature switch 8 blue rose 1 mm DDC fuel solenoid hold 9 green 1 5 mm DDC fuel solenoid pull 20 pink 2 5 mm DDC fuel solenoid com 17 black 2 5 mm B terminal alternator starter motor 21 red 6 mm DDC R terminal alternator 18 wit 1 5 mm DDC L terminal alternator 19 orange 1 5 mm D...

Page 39: ...DIAGRAMS DRAWINGS EN W SQ6 8 12 16 for mobile applications December 2016 39 4 7 AC WIRING DIAGRAM 230V 50HZ Fig 39 AC wiring diagram ...

Page 40: ...or mobile applications EN 4 8 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 230VAC Fig 41 Electrical diagram fan control using 230V AC radiator fans with two speeds fans optional Fig 40 Electrical diagram for standard fan control using 230V AC radiator fans ...

Page 41: ...RAMS DRAWINGS EN W SQ6 8 12 16 for mobile applications December 2016 41 4 9 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 12 24 VDC Fig 42 Electrical diagram fan control using 12V or 24V DC radiator fans optional ...

Page 42: ...an electronic governor will bring more power So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled WhisperPower engines The actuator controls the RPM directly on the fu...

Page 43: ... EN W SQ6 8 12 16 for mobile applications December 2016 43 4 11 REMOTE CONTROL PANEL DRAWINGS Fig 44 WhisperPower remote panel The remote panel comes in a carton that can be used as a template to drill the mounting hole ...

Page 44: ...OX DIMENSIONS W SQ6 exhaust 1 length 80 5 cm 31 7 fuel hose 5 16 8 mm width 52 5 cm 20 7 radiator alternator 3 4 19 mm height 58 0 cm 22 8 radiator engine 1 25 4 mm weight 240 kg 530 Lbs battery AWG 2 25 mm battery AWG 2 25 mm POWERCABLES ISO 13297 annex A 3 x AWG 12 4 mm not included REMOTE CONTROL 15 meter 45 ft 8 wire communication cable included ...

Page 45: ... W SQ8 BOX DIMENSIONS W SQ8 exhaust 1 length 900 mm 35 4 fuel hose 5 16 8 mm width 575 mm 22 6 radiator alternator 3 4 19 mm height 640 mm 25 2 radiator engine 1 32 mm weight 335 kg battery AWG 2 25 mm battery AWG 2 25 mm POWERCABLES ISO 13297 annex A not included 3x6 mm not included REMOTE CONTROL 15 meter 8 wire communication cable included ...

Page 46: ...TIONS W SQ12 BOX DIMENSIONS W SQ12 exhaust 1 length 1060 mm 41 7 fuel hose 5 16 8 mm width 575 mm 22 6 radiator alternator 3 4 19 mm height 640 mm 25 2 radiator engine 1 32 mm weight 380 kg battery AWG 2 25 mm battery AWG 2 25 mm POWERCABLES ISO 13297 annex A 3x10 mm not included REMOTE CONTROL 15 meter 8 wire communication cable included ...

Page 47: ... exhaust 1 length 1160 mm 45 7 fuel hose 5 16 8 mm width 680 mm 26 8 radiator alternator 3 4 19 mm height 700 mm 27 6 radiator engine 1 32 mm weight 454 kg battery 35 mm battery 35 mm A template to drill the mounting holes of the W SQ16 is included in the delivery POWERCABLES ISO 13297 annex A 3x16 mm not included REMOTE CONTROL 15 meter 8 wire communication cable included ...

Page 48: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com info whisperpower com ...

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