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USERS MANUAL FOR MOBILE APPLICATIONS

W-SQ16

- 1500 RPM -

Mobile diesel generating set 230V / 50Hz

Digital Diesel Control

WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
Nederland
Tel.: +31-512-571550
Fax.: +31-512-571599
www.whisperpower.eu

Art.nr. 40200491

V1 January 2009

Summary of Contents for W-SQ 16

Page 1: ...CATIONS W SQ16 1500 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu Art nr 40200491 V1 January 2009 ...

Page 2: ... Features 9 2 3 2 Remote control 9 2 3 3 Documentation 9 2 4 Components 10 2 4 1 Main components to identify 11 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 12 2 5 3 Digital Diesel Control system 12 2 5 4 Battery charger 12 2 5 5 Alarms and shut down 12 2 5 6 Control 13 2 5 7 Remote control 13 2 5 8 Hour counter 13 ...

Page 3: ...4 3 Regular maintenance 23 4 3 1 Maintenance schedule 24 4 3 2 Putting out of service 24 5 TROUBLE SHOOTING 225 5 1 Alternator electrical faults 225 5 1 1 General 225 5 1 2 Trouble shooting table alternator 26 5 2 Engine faults 27 5 2 1 General 27 5 2 2 Trouble shooting table engine 28 5 2 3 Warnings 30 5 2 4 Service address 30 5 3 Special procedures alternator 31 5 3 1 Residual voltage check exci...

Page 4: ...on 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 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 o...

Page 5: ... a credit will not be issued For 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...

Page 6: ...ess than specified on the identification plate 3 VOLTAGE shows the nominal voltage This voltage should be within the specified tolerance at the nominal frequency 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 1500 rpm 5 CURRENT shows the maximum current that is acceptable at the specified frequency voltage and power factor 6 WEIGHT shows the net d...

Page 7: ...to 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 depending on the application it could be necessary to take measures...

Page 8: ... smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand INCASEOFFIRE DONOTOPENSOUNDSHIELD TOAVOIDSERIOUSINJURYORDEATHFROM FIRE IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS SHUTDOWNENGINES GENERATORSETSANDBLOWERS PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT THROUGH HERE FIREEXTINGUISHERPORT BREAK Fig 2 Fire extinguisher port In case of fire do not open...

Page 9: ...des a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s sides The set is not self contained and is only operable after proper installation using additional accessories and installation...

Page 10: ...mponents W SQ16 Fig 4 Rear view main components W SQ16 01 Hoist eye rear 02 Hoist eye front 03 Thermostat housing 04 Exhaust manifold watercooled 05 Exhaust 07 Rubber engine mounting 09 Filler cap engine oil 10 Rocker cover 11 Filler cap engine coolant 12 Temperature switch coolant 13 Engine oil pressure switch 14 Engine serial number ...

Page 11: ...wer output 26 Engine oil filter 27 Oil sump handpump 28 Failsafe 30 Glowplug 4x 31 Fuel injector 4x 32 Fuel solenoid 33 Engine Oil Dipstick 34 Fuel bleeding screw 35 Starter motor solenoid 36 Starter motor 37 Fuel lift pump for manual priming 38 Fuel injection pump 39 Battery negative 35mm2 40 Battery positive 35mm2 41 Fuel out Ø8mm 42 Fuel in Ø8mm 43 Coolant engine in 44 Coolant alternator in 45 ...

Page 12: ...oad switching to relieve the burden on the engine The alternator is water cooled and the cooling liquid is cooled by a radiator Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The W SQ16 generating set is based on the Mitsubishi S4Q2 4 cylinder diesel engine The engine is indirectly injected The engine is water cooled and the...

Page 13: ... 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 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 f...

Page 14: ...W Cooling system By means of a radiator Fuel lift pump engine electric pump 12 V DC additional pump available upon request Starting battery optional 110 Ah 12V Fuel consumption 2 7 litre hour load dependent Control Digital Diesel Control including automatic start stop ELECTRICAL SPECIFICATIONS Output voltage 230V 50 Hz alternating current AC single phase Output rating 16 kVA 16kW at power factor c...

Page 15: ...DDC oil temperature switch 7 blue 1 mm2 LCP oil temperature switch 7 blue black 1 mm2 DDC exhaust temperature switch 8 blue green 1 mm2 LCP exhaust temperature switch 8 blue pink 1 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 ...

Page 16: ...INFORMATION 16 January 2009 W SQ16 for mobile applications EN 2 5 15 Lay out control wiring Fig 10 Electrical Diagram control wiring W SQ16 Optional control for two speeds fans See chapter 4 8 ...

Page 17: ...INFORMATION EN W SQ16 for mobile applications January 2009 17 2 5 16 Electrical diagrams 230 V AC 50 Hz Fig 11 Electrical diagram 230V ...

Page 18: ...VDC K1 K2 230 115VAC 200VA TRAFO 230VAC Fig 13 Electrical diagram fan control using 230V AC radiator fans with two speeds fans optional FUSE 5A FUSE 6 3A FUSE 6 3A FUSE 5A FUSE 5A 15 16 5 6 7 8 13 14 11 1 4 2 3 K2 K1 K2 K1 BAT 12V PUMP 12V GENERATOR 230VAC L1 K1 BAT 12V GENERATOR 230VAC N 230VAC 230VAC 45 35 C 80 70 C THERMOSTAT COOLER ENGINE GENERATOR RADIATOR COOLER ENGINE RADIATOR COOLER GENERA...

Page 19: ...d to 70 of maximum load Stopping generator 1 Switch off all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load and let it run for approx 5 minutes 2 Press the STOP button 3 Switch to an other AC power source if available If a Mass Systemswitch is installed this...

Page 20: ...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 SQ16 is designed so as not to overheat even under extreme conditions Do not run th...

Page 21: ... 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 ...

Page 22: ...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 4 2 6 Readjustment V beltplacing oil filter The alternator bracket allows for readjust of the V belt Deflections should be 10 mm refer to fig 19 4 2 7 Air filter element The interval for cleaning of the air filter element figure 20...

Page 23: ...lant pump Replace the oil filter Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 hours Isolate the fuel supply and change the element EVERY 500 HOURS Check the air strainer element and the air filter element Replace the impeller of the alternator coolant pump When replacing the impeller the gasket between the pump case and the cover shoul...

Page 24: ...lean radiators 1000 hours Replace or clean the air strainer element 2000 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 fu...

Page 25: ...he 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 set...

Page 26: ...tion it is ok Generator is overloaded Switch off a load part off consumers Engine is not reaching the rated RPM Refer to engine RPM problems Defective capacitor Check capacitor and replace if necessary refer to special procedures Generator voltage too high more than 245V 130V Engine is running too fast RPM too high Check engine speed and adjust refer to special procedures Over energising due to de...

Page 27: ...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 28: ... 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 inspect the outlet port When little rust in the port clean the valve by taking off the valve spring and rotate...

Page 29: ...s after 10 up to 30 seconds Protection system stops the engine this can be caused by oil pressure failure lack of cooling water exhaust temperature alarm Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure 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 O...

Page 30: ...er Exhaust blocked Check the exhaust system Faulty fuel pump Check and replace if nescessary 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 and have the engine overhauled Over temperature Overload Take away the overload Low level of coolant or ...

Page 31: ...terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replace the diode 5 3 3 Winding resistant values I...

Page 32: ...rrect setting assembly refer to fig 25 The screw is to be locked in position with the lock nut 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts Both procedures have to be carried out with a cold engine When both procedures are carried out be sure to retighten the cylinder head bolts before adjusting the valve clearance When retightening the cylinder head bolts drain the coo...

Page 33: ...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 can be disassembled according to exploded view below figure 28 3 To take the generating set out of the soundshield 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 th...

Page 34: ...SPARE PARTS LIST 34 January 2009 W SQ16 for mobile applications EN Figure 28 exploded view sound shield W SQ16 ...

Page 35: ...cs 50206264 O ring 50206263 Seal 50206262 Shim 50206271 Ring 50206265 Cam 50206269 Screw 50206265 Washer 50206274 Screws 6pcs 50209018 Cover 50206255 40209010 Pump repair kit B consisting of Bearings 2 pcs 50206264 O ring 50206263 Seal 50206262 Ring 50206265 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50201482 Alternator bearing includin...

Page 36: ...SPARE PARTS LIST 36 January 2009 W SQ16 for mobile applications EN Figure 29 water pump complete Whisper Power type M16 ...

Page 37: ...MAINTENANCE LOG EN W SQ16 for mobile applications January 2009 37 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Page 38: ...NOTES 38 January 2009 W SQ16 for mobile applications EN NOTES ...

Page 39: ...NOTES EN W SQ16 for mobile applications January 2009 39 ...

Page 40: ...Kelvinlaan 82 9207 JB Drachten The Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl ...

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