Whisper Tech GEN PPS16 User Manual Download

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MAINTENANCE

Introduction .................................................................................................................................. 45

Maintenance Schedule............................................................................................................ 45,46

Removing the Enclosure Lid ........................................................................................................ 47

General Checking ........................................................................................................................ 48

Checking the Fuel ........................................................................................................................ 49

Bleeding the Fuel Line ............................................................................................................ 50-52

Cleaning the Fuel Pump Filter................................................................................................. 53-54

Checking the Coolant................................................................................................................... 55

Bleeding the Coolant Circuit.................................................................................................... 56-59

Checking Battery Bank Connections....................................................................................... 60,61

Replacing the Glow Plug......................................................................................................... 62,63

Replacing Fuses ..................................................................................................................... 64-66

Replacing the FID ................................................................................................................... 67-69

Replacing the Oxygen Sensor ................................................................................................ 70,71

Replacing the Evaporator........................................................................................................ 72-74

Flushing the Exhaust Heat Exchanger.................................................................................... 75-77

TROUBLE SHOOTING

Correcting Faults..................................................................................................................... 78-82

Correcting Warnings ............................................................................................................... 82,83

Resetting the WhisperGen ...................................................................................................... 84,85

SERVICE DETAILS

................................................................................................................ 86-89

EC CONFORMITY

.................................................................................................................. 90,91

INDEX

..................................................................................................................................... 92,93

Summary of Contents for GEN PPS16

Page 1: ...PPS16 Marine and Land Version Kerosene or Diesel Fuel 12 or 24 Volt Battery Bank Capacity WHISPER TECH LIMITED R 2 FUEL OFF ON Personal Power Station FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START R R ...

Page 2: ... WhisperGen Personal Power Station and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited Copyright 2002 Whisper Tech Limited All rights reserved Printed in New Zealand R Title User Manual PPS16 DC Part Number DO 40015 D C N Number 464 Application This manual applies to WhisperGen model numbers PPS16 12 MD PPS16 24 MD and PPS16 24 LK in the following installations ...

Page 3: ...WhisperGen representative to provide such services Do not attempt to install commission or service the WhisperGen yourself unless you have been so approved Whisper Tech accepts no liability for personal injury or property damage resulting from faulty installation commissioning and servicing For each installation operating conditions will vary sometimes greatly Such variations may affect the Whispe...

Page 4: ...24 Manual Stopping 20 Emergency Stopping 21 Setting the Maximum Run Time 22 24 Remote Controlling 25 26 Managing the Battery Bank 27 29 Stages of Charging 27 Auto Charging the Battery Bank 28 Bulk charging the Battery Bank 29 Managing Heat Generation 30 31 Setting the Coolant Temperature 30 Turning On Heat Management 31 Clearing Faults and Warnings 32 34 Adjusting the LCD 35 36 Adjusting the Contr...

Page 5: ... 55 Bleeding the Coolant Circuit 56 59 Checking Battery Bank Connections 60 61 Replacing the Glow Plug 62 63 Replacing Fuses 64 66 Replacing the FID 67 69 Replacing the Oxygen Sensor 70 71 Replacing the Evaporator 72 74 Flushing the Exhaust Heat Exchanger 75 77 TROUBLE SHOOTING Correcting Faults 78 82 Correcting Warnings 82 83 Resetting the WhisperGen 84 85 SERVICE DETAILS 86 89 EC CONFORMITY 90 9...

Page 6: ...ity regarding this requirement What it Does The WhisperGen PPS16 is a Personal Power Station that generates heat and electrical energy simultaneously The WhisperGen is capable of charging and managing a lead acid battery bank to provide a DC electrical power supply It also provides heat energy in the form of hot coolant for space heating and domestic hot water generation Note Not all elements of t...

Page 7: ...ing The burner consumes air and fuel The flow rate of air and fuel into the burner is optimised by a microcomputer This maximises combustion efficiency and minimises exhaust emissions The microcomputer automatically controls all WhisperGen functions and displays real time information about the system on a control panel from which the user can also alter operating options BATTERY BANK AND OR ELECTR...

Page 8: ...es Refrigerator Washing Machine Microwave Oven Video Recorder Television Music Centre Etc 12 or 24 Volt DC 1 3 4 5 6 7 2 8 9 20 17 18 19 21 16 11 15 22 13 12 23 24 14 10 WTL0003 FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START R ...

Page 9: ...STOPPING RUNNING STARTING STANDBY STOP START Electrical Appliances DC Appliances Refrigerator Washing Machine Microwave Oven Video Recorder Television Music Centre Etc 12 or 24 Volt DC 1 3 4 5 6 7 2 20 17 18 19 21 16 11 15 13 12 23 24 25 14 10 WTL0004 Foul water drain R ...

Page 10: ...r pump 10 Electronics enclosure 11 Current shunt 12 DC appliances 12 24 Volt 13 Inverter DC to 230 110 Volt AC 14 Electrical appliances 230 110 Volt AC 15 Battery bank 12 24 Volt 16 Circuit breaker 17 Fuel tank 18 Fuel filter 19 Fuel pump 20 Exhaust gases vented into atmosphere 21 Condensate drain 22 Seawater 23 Control panel 24 Remote start stop switch optional 25 External heat dump radiator opti...

Page 11: ...t Control Manual Manual start stop from control panel External Optional remote starting via external switch Timer thermostat or on off switch may be used Auto charge Optional automatic battery bank charging Starts and stops at preset discharge levels Heat management Optional automatic heat generation to maintain coolant temperature Coolant temperature is user selectable External heater Optional co...

Page 12: ...panel of the enclosure Fuel Rp 1 8 ISO 7 1 BSPP 1 8 Heat exchangers Rp 3 4 ISO 7 1 BSPP 3 4 Exhaust Rp 1 1 4 ISO 7 1 Exhaust must be vented outside occupied areas Exhaust flushing G 3 4 ISO 228 1 Face sealing fitting required Condensate draining 12 7mm O D plain tube Battery bank 35mm screw terminals External switch 0 5 to 2 5mm screw terminals PC RJ 45 Via RS485 to RS232 converter Physical Dimens...

Page 13: ...R 8 Summary of Parts 2 FUEL OFF ON FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0005 R Personal Power Station R 9 10 11 12 13 1 2 3 4 5 6 7 8 ...

Page 14: ...nd controlling operating parameters 5 Fuel Line The tube through which fuel is supplied to the burner 6 Marine Heat Exchanger Marine version only A device that transfers excess heat energy from the coolant to seawater 7 Earthing Strap The earthing cable for the glow plug 8 Air Blower The fan that supplies air to the burner 9 Oxygen Sensor A sensor that feeds back to the microcomputer the air fuel ...

Page 15: ... STANDBY the WhisperGen is ready to start STARTING the WhisperGen is starting RUNNING the WhisperGen is operating STOPPING the WhisperGen is stopping FAULT a fault or warning is present AUTOCHARGE the battery bank auto charging function is turned on EXT CONTROL external control of the WhisperGen is enabled HEAT MANAGE the heat management function is turned on 5 LCD Panel A liquid crystal display t...

Page 16: ...t Incorrect installation or servicing can damage the WhisperGen and property cause personal injury and or void the warranty WTL0000 Always heed warning signs on the WhisperGen The engine contains high pressure nitrogen and some internal surfaces are hot FUEL OFF ON Critical Applications Other Supply WTL0016 R Personal Power Station Never use the WhisperGen as the sole source of electrical power fo...

Page 17: ... fuel line after filling a completely empty fuel tank WTL0056 The cooling system is vital to the performance of the WhisperGen If there are leakages in the cooling circuit or the water is not flowing inform an authorised WhisperGen agent immediately WTL0057 Use only the recommended coolant mixture Using an incorrect type of coolant fluid can cause serious corrosion in the WhisperGen WTL0058 Ensure...

Page 18: ...the WhisperGen may be disrupted FUEL OFF ON R Personal Power Station WTL0065 Do not drill holes in the enclosure Air circulation through the WhisperGen may be disrupted WTL0066 Do not modify the piping for the fuel exhaust and cooling systems of the WhisperGen without first consulting an authorised WhisperGen agent FUEL OFF ON R Personal Power Station WTL0067 Isolate the WhisperGen from the batter...

Page 19: ...rd on the top FUEL OFF ON R Personal Power Station WTL0060 Do not expose the WhisperGen to large physical impacts FUEL OFF ON R Personal Power Station WTL0061 Do not expose the WhisperGen to excessive vibration FUEL OFF ON R Personal Power Station WTL0062 Do not expose the WhisperGen to extreme temperatures The ambient temperature should not exceed 40 C or fall below 10 C FUEL OFF ON R Personal Po...

Page 20: ...007 Before the WhisperGen is transported by air or disposed fluids in it must be drained and the engine must be depressurised Consult your authorised WhisperGen service agent for advice FUEL OFF ON R Personal Power Station WTL0070 In some countries it is a requirement that a maintained fire extinguisher be permanently located alongside an installed WhisperGen Consult your local authority for infor...

Page 21: ...r WhisperGen starting method Heat Manage ON Heat Manage OFF Max Run Hours 25 Max Run Hours 25 Max Run Hours 25 Max Run Hours 25 Manual start Stops when Max Run Hours value is reached even if the battery bank is not yet fully charged Continues running until stopped by the user Stops when the battery bank is charged or when Max Run Hours value is reached which ever comes first Continues running unti...

Page 22: ... Mode Max Run Hours Edit to clear Current Warning Last Warning 2nd Last Warning Current Fault Last Fault 2nd Last Fault Start Code Stop Code User Menu Battery Volts Battery Amps Batt Amp hrs Battery Watts Gross Watts Runtime Min Hour Meter Of Starts Warning Code Extra Info Menu Installation Menu Fault Warning Menu Coolant 1 Bleed Fuel Bleed Air Bleed Heat Exchanger Nozzle Bleed Coolant 2 Bleed Ena...

Page 23: ...ction entitled Clearing Faults and Warnings If nothing is displayed on the control panel check that the WhisperGen is connected to the battery bank and that the 3A fuse F2 position as marked on PCB is not blown 2 Turn on the fuel valve R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Battery Watts 563 FUEL OFF ON WTL0011 OFF ON FUEL R Personal Power S...

Page 24: ... charged Once the battery bank is fully charged the WhisperGen automatically stops and returns to the standby mode as indicated by a lit STANDBY indicator if the default settings are used i e Auto charge mode If the WhisperGen is in Heat Manage mode the WhisperGen will continue to run for as long as there is a heat demand If you press START while the WhisperGen is in the process of stopping it wil...

Page 25: ...e minutes during which the engine is cooled down When the WhisperGen has fully stopped the STANDBY indicator lights up and the control panel displays WhisperGen The WhisperGen must be in the standby mode before it can be started again If a remote switch has been installed to control the WhisperGen you can also stop the WhisperGen with the remote switch refer to section entitled Remote Controlling ...

Page 26: ...again The WhisperGen will attemp to re start if auto restart is enabled If the fuel valve remains off the attempt will fail It is recommended that once the fuel valve has been turned off and the stop button on the control panel activated this will cancel all auto restarts FUEL OFF ON WTL0012 OFF ON FUEL R Personal Power Station Note The WhisperGen must complete a cool down sequence there is no way...

Page 27: ...rGen 1 Access the default display on the control panel by pressing repeatedly See section entitled Displaying System Information Displaying Information 2 Press to display the first item on the main menu the User Menu R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Battery Watts 563 R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING ...

Page 28: ...ours 5 Press to begin editing the maximum operating time of the WhisperGen R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Heat Manage R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Max Run Hours ...

Page 29: ...not yet fully charged If the Max Run Hours setting is left at its default value of 25 no maximum operating time condition is imposed the WhisperGen will run continuously until the battery bank is fully charged Note that the Max Run Hours setting applies only if the WhisperGen is started manually or from a remote switch It does not apply if the WhisperGen automatically starts by itself as a result ...

Page 30: ...1 to 3 of the procedure outlined in the section entitled Setting the maximum Run Time 2 Press to scroll down to Ext Control 3 Press to begin editing the external control setting 4 Press to select ON The EXT CONTROL indicator lights up R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Ext Control R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNI...

Page 31: ...to pressing START or STOP on the control panel refer to section entitled Starting the WhisperGen and Stopping the WhisperGen For a summary on operating options refer to the Quick Reference Operating Options Setting Control Options Control Logic 1 Starting only The WhisperGen will start when the remote switch is closed and will continue running even if the remote switch is then opened 2 Starting an...

Page 32: ...t the maximum rate The voltage typically rises 2 or 3 Volts while the current is maintained at a fixed level Bulk charging Absorption charging Float charging Time Time Voltage across Battery Bank Terminals Current Supplied to Battery Bank Absorption charging The battery bank is about 80 charged at the beginning and the voltage is maintained at a fixed level to fully charge it The current decreases...

Page 33: ...me 2 Press to scroll down to Auto charge 3 Press to begin editing the auto charge setting 4 Press to select ON The AUTOCHARGE indicator lights up 5 Optional press repeatedly to return to the default display You can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING ST...

Page 34: ...ank before stopping For a summary on operating options see section entitled Quick Reference Operating Options Bulk charging the Battery Bank While the WhisperGen is running you can start a new cycle of battery bank charging that is return to bulk charging the battery bank see section Stages of Charging This can be done regardless of auto charging and heat management settings To bulk charge the bat...

Page 35: ...1 to 3 of the procedure outlined in section entitled Setting the Maximum Run Time 2 Press to scroll down to Temp Setpoint 3 Press to begin editing the coolant temperature setting 4 Press or to select the coolant temperature The values shown on the control panel are in C 5 Optional press repeatedly to return to the default display You can also let the default display re appear automatically by allo...

Page 36: ...he heat management setting 3 Press to turn the Heat Manage option ON The HEAT MANAGE indicator lights up 4 Optional press repeatedly to return to the default display You can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel With the Heat Manage option turned ON the WhisperGen if started manually or from a remote switch will run contin...

Page 37: ... be cleared even if the physical cause of it has not been corrected It is possible for the WhisperGen to detect a warning and then subsequently a fault If this occurs the WhisperGen will attempt to clear the fault and restart itself the fault needs to be cleared before the WhisperGen can be started again It is however recommended that the cause of the warning be determined and corrected as soon as...

Page 38: ... entitled Setting the Maximum Run Time 4 Press to scroll down to Fault Warning Menu 5 Press to display the first item on the Fault Warning Menu R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Fault Warning Menu R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Warning Code 102 Edit to clear Code of prevai...

Page 39: ...ay You can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Warning Code 102 Edit to clear R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Warning Code 0 ...

Page 40: ...ast is achieved To decrease the contrast of the LCD Hold down and press repeatedly until the desired contrast is achieved If the battery bank is disconnected from the WhisperGen LCD contrast settings are retained for up to approximately one month after the disconnection R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 R FAULT AUTOCHARGE EXT CONTROL HE...

Page 41: ...ieved Three levels of backlighting are available namely high low and off If no keys are pressed the backlight will be automatically turned off after four minutes It will be automatically turned on again when a key is pressed If the battery bank is disconnected from the WhisperGen backlighting settings are retained for up to approximately one month after the disconnection R FAULT AUTOCHARGE EXT CON...

Page 42: ...The quantity of electrical power in Watts supplied to the battery bank Positive values indicate charging and negative values discharging 7000 to 1000 Watts Gross Watts The gross electrical power in Watts from the WhisperGen generator before power to auxiliary devices such as the air blower and pumps 200 to 1000 Watts Runtime Min The total operating time in minutes since starting 0 to 999 999 minut...

Page 43: ...ction entitled Setting the maximum run time 1 to 24 hours or 25 hours for continuous operation default Fault Warning Menu Parameter Meaning Typical Range Warning Code Edit to clear The current warning code and the warning clearing function see section 2 8 100 to 199 Current Warning The code of the prevailing warning if there is one 100 to 199 Last Warning The code of the last warning 100 to 199 2n...

Page 44: ...ting element located inside the WhisperGen enclosure 0 to 70A Clamp Voltage The voltage setting of the clamp system 12V 12 2 to 16 3V 24V 24 85 to 32 7V Exhaust Temp The temperature in C of exhaust gases between the burner and exhaust heat exchanger 10 to 550 C FID Current uA The current in µA flowing between the FID flame ionisation detector electrode and the burner shell A large current indicate...

Page 45: ...umber Installation Menu Parameter Meaning Typical Range Heat exchanger Nozzle Bleed Spraying water through the heat exchanger to clean internal cavities On for 1 sec Air Bleed Blowing air through the burner and exhaust system ON or OFF default Fuel Bleed The fuel bleeding function see section entitled Bleeding the Fuel Line The water pumps may start when the fuel line is bled ON or OFF default Coo...

Page 46: ...ess repeatedly until one of the default display parameters appear For example if Alt Current a parameter of the extra info menu is initially displayed pressing twice returns to the default display To display a menu at a lower level 2 Press For example if Battery Volts a parameter in the default display is displayed initially then to display the main menu press once as shown R FAULT AUTOCHARGE EXT ...

Page 47: ...layed initially then to display Alt Current press twice To scroll down within a menu 5 Press For example if Alt Current is displayed initially then to display Coolant Temp press three times R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Alt Current R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Coolan...

Page 48: ...itled Displaying System Information Displaying Information For example if you wish to edit the battery bank auto charging setting then display Auto charge on the control panel by pressing twice followed by twice from the default display 2 Press to begin editing the setting of the parameter The existing setting of the parameter will be displayed In the above example either ON or OFF will be display...

Page 49: ...eatedly to return to the default display You can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Auto charge On R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Battery Watts 563 ...

Page 50: ...on General checking Every six months Flushing the exhaust heat exchanger See section Flushing the exhaust heat exchanger Every three months You should read and understand all safety precautions before operating or maintaining your WhisperGen For spare parts kit supplied refer to your authorised WhisperGen service agent for further details Before carrying out maintenance the Enable Starts option in...

Page 51: ...nt circuit When there is a coolant flow fault Replacing the glow plug See section Replacing the glow plug When a glow plug circuit fault arises and the glow plug fuse is not blown Replacing fuses See section Replacing fuses When fuses are blown Replacing the FID See section Replacing the FID When ignition or flame faults occur repetitively Replacing the oxygen sensor See section Replacing the oxyg...

Page 52: ...per plastic hooks on both sides of the WhisperGen 2 Carefully lift the enclosure lid When replacing the lid hook it over the back of the enclosure base and swing it down over the front Ensure the lid is well seated on the rubber seal Then connect the rubber rings to the hooks WTL0018 WTL0019 Do not touch the surfaces that are labelled as hot and do not operate the WhisperGen without the enclosure ...

Page 53: ...closure Fluids and white residue deposited at the bottom of the WhisperGen enclosure are often an indication of leakage 10 Check for abnormal noises There should not be excessive rattling sounds 11 Check that the rubber hoses and the external red burner seal are not cracked or worn 12 Check the battery bank connections 13 Check that the drain holes in the bottom corners of the enclosure base are n...

Page 54: ...eplenish fuel if necessary taking care not to spill any on or in the vicinity of the WhisperGen For WhisperGen s equipped with diesel burners For WhisperGen s equipped with kerosene burners 4 Replace the fuel tank cap If the fuel tank was empty and a fuel related error message is displayed on the control panel you will need to bleed the fuel line before the WhisperGen can be operated normally agai...

Page 55: ... the fuel line air bubbles that could cause the WhisperGen to malfunction After filling an empty fuel tank you must bleed the fuel line to remove any air bubbles that might be trapped in it The coolant and seawater pumps may start when the fuel line is bled marine version only To prevent unintentional starts of the WhisperGen heed the warning given at the beginning of this section Do not touch the...

Page 56: ...tre of fuel 6 Access the Main Menu on the control panel follow the first two steps of the procedure outlined in the section entitled Stopping the WhisperGen Setting the maximum run time 7 Press to scroll down to Installation Menu 2 WTL0022 WTL0023 Fuel Container Plastic Hose Fuel Line R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Installation Menu ...

Page 57: ...f fuel must be bled 11 Optional press repeatedly to return to the default display You can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel 12 Reconnect the fuel line to the evaporator Finger tighten the nut against the shoulder Using a spanner tighten turn only 13 Ensure that there is no leakages 14 Replace the enclosure lid The Whis...

Page 58: ...equently or if the power output is constantly low To clean the fuel filter 1 Turn off the fuel tank valve and the WhisperGen fuel valve 2 Place a container below the fuel pump to collect fuel spillage 3 Remove the fuel line from the brass end of the fuel pump 4 Undo the cylindrical brass fitting Fuel Tank Fuel Tank Valve Auxiliary In line Filter Fuel Pump OFF ON FUEL WTL0025 Fuel Pump WTL0026 WTL0...

Page 59: ...ure the brass fitting to the fuel pump making sure that the o ring is correctly seated 8 Secure the fuel line to the fuel pump 9 Turn on the fuel tank and WhisperGen fuel valves 10 Bleed the fuel line 11 Check that there is no fuel leakage If there is another fuel filter installed external to the fuel pump it should be cleaned also follow the instructions provided by the WhisperGen service agent w...

Page 60: ... if necessary Use a high quality automotive glycol based corrosion inhibited antifreeze that is designed for aluminium engines Follow the dilution recommendation of the manufacturer 4 Replace the coolant header tank cap The cooling system of the WhisperGen is vital to its performance If the coolant level is not maintained correctly damage may occur WTL0030 Minimum Inadequate Outlet Coolant cold Co...

Page 61: ...scroll down to Installation Menu Filling a coolant header tank in which the coolant level has fallen below the outlet level of the tank may introduce into the coolant circuit air bubbles that could cause the WhisperGen to malfunction Should this occur bleed the coolant circuit To prevent unintentional starts of the WhisperGen heed the warning given at the beginning of this section Do not touch the...

Page 62: ... pump will be turned on to bleed the coolant circuit R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Hx Nozzle Bleed R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Coolant Bleed 1 R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Coolant Bleed 1 ON ...

Page 63: ...five minutes press to turn it off 12 Allow the coolant to rest for one minute 13 Repeat steps 8 to 12 until coolant bleeds out of the coolant bleeding valve without air bubbles 14 Close the coolant bleeding valve securely WTL0031 Oxygen Sensor Exhaust Heat Exchanger Coolant Bleeding Valve R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Coolant Bleed ...

Page 64: ...to marine units only The seawater circuit may need to be bled if the seawater pump inlet has been lifted above seawater level To bleed the seawater circuit follow steps 1 3 4 5 6 7 and 8 above but turn on Coolant Bleed 2 instead of Coolant Bleed 1 in the Installation Menu The seawater pump and the coolant pump will be turned on to bleed both the seawater and coolant circuits for one hour after whi...

Page 65: ...d every three months To check the battery bank connections 1 Access the battery bank managed by the WhisperGen and ensure that the battery bank connections as shown below are intact and clean 2 Check that the circuit breaker is closed 3 Replace the voltage fuse if it has blown 4 Check that the electrical insulation of the wires cables is intact 5 Remove the enclosure lid FUEL OFF ON Current Shunt ...

Page 66: ...y closing the circuit breaker If an electrical fault persists or if the electrical insulation of the wires cables is worn contact your authorised WhisperGen service agent If stopping the WhisperGen to re secure a wire cable heed the warning given at the beginning of this section to prevent unintentional starts of the WhisperGen FUEL OFF ON 2 WTL0033 Green White Red Black Violet Current Sensing Wir...

Page 67: ... replace the glow plug 1 Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit 2 Remove the enclosure lid and wait for the engine to cool 3 Remove the nut on top of the glow plug and detach the wire 4 Unscrew the glow plug using a 22mm spark plug size spanner To prevent unintentional starts of the WhisperGen heed the warning given at the beginning of this section Do ...

Page 68: ...fasten the nut securely 8 Replace the enclosure lid The old glow plug can be returned to your authorised WhisperGen service agent for checking The glow plug may be hot WTL0035 Glow Plug Do not touch the wire coil on the new glow plug as this will shorten its life span It is advisable to keep a spare glow plug with the WhisperGen at all times Glow plugs used on the WhisperGen should be obtained fro...

Page 69: ...older WhisperGen fuses can be obtained from electrical hardware suppliers or your authorised WhisperGen service agent Before replacing a fuse find out the cause of the fault Otherwise damage to equipment may occur If you are unsure of the cause of the fault contact your authorised WhisperGen service agent for assistance FUEL OFF ON Voltage Fuse Voltage Sensing Wires Fuse Holder Fuse Inside WTL0036...

Page 70: ... enclosure lid 2 Disconnect the WhisperGen from the battery bank by opening the circuit breaker 3 Release the four screws securing the cover of the electronics enclosure and remove the cover Before replacing a fuse find out the cause of the fault Otherwise damage to equipment may occur If you are unsure of the cause of the fault contact your authorised WhisperGen service agent for assistance To pr...

Page 71: ...id 8 Reconnect the WhisperGen to the battery bank by closing the circuit breaker WhisperGen fuses can be obtained from electrical hardware suppliers or your authorised WhisperGen service agent Current Rating in Ampere External Auxillary Seawater Pump Coolant Pump Circuits Internal Coolant Pump Circuit Fuel Pump Fuel Shut off Valve Circuits Air Blower Oxygen Sensor Flushing Circuits Control Panel M...

Page 72: ...orator 5 Lift the FID out of the evaporator gripping the FID below the brass nut with a pair of pliers if necessary Twist the FID from side to side while pulling it straight up 6 Check the FID for cracks and that the electrode tip at the bottom of the FID is protruding by at least one millimetre Also check that there is electrical continuity between the brass nut and To prevent unintentional start...

Page 73: ...FID is re usable 7 Insert a straight length of rigid wire vertically into the FID hole The wire should go down 135 10mm 8 With the wire touching the base of the FID hole mark on the wire the top level of the evaporator WTL0040 Replace if cracked Replace if less than 1mm Replace if there is electrical discontinuity open circuit WTL0041 Evaporator Wire WTL0042 Evaporator Wire Mark here ...

Page 74: ... position of the clip insert the FID into the FID hole gripping the FID below the brass nut with a pair of pliers if necessary Twist the FID from side to side while pushing it straight down 12 Fasten securely the FID clip to the evaporator and the wire terminal to the FID 13 Replace the enclosure lid The WhisperGen may now be started as required WTL0043 Evaporator Wire Second mark First mark 6 mm ...

Page 75: ... STANDBY indicator on the control panel is lit 2 Remove the enclosure lid and wait for the engine to cool 3 Detach the electrical connector of the oxygen sensor by squeezing the two side clips 4 Undo the nut that holds the oxygen sensor in place To prevent unintentional starts of the WhisperGen heed the warning given at the beginning of this section Do not touch the surfaces that are labelled as h...

Page 76: ... the oxygen sensor 7 Finger tighten the nut that holds the oxygen sensor in place Using a spanner tighten 1 turns only 8 Re fit the electrical connector 9 Replace the enclosure lid The WhisperGen may now be started as required WTL0047 Do not touch the sensing tip of the oxygen sensor as this will shorten its life span WTL0048 Do Not Touch Here It is advisable to keep a spare oxygen sensor with the...

Page 77: ...eral you should check and or replace the FID and oxygen sensor before deciding to replace the evaporator To replace the evaporator 1 Remove the FID 2 Remove the glow plug 3 Turn off the WhisperGen fuel valve 4 Unscrew the fuel line fitting on top of the burner FUEL OFF ON WTL0012 OFF ON FUEL R Personal Power Station 2 WTL0022 ...

Page 78: ... four screws on top of the evaporator 6 Lift the evaporator out of the burner 7 Place the evaporator gasket on the new evaporator ensuring that all the holes line up WTL0049 Evaporator top view Burner WTL0050 WTL0051 ...

Page 79: ... shoulder Using a spanner tighten turn only 12 Ensure that there is no leakages 13 Refit the FID 14 Bleed the fuel line Refer to section entitled Bleeding the Fuel Line 15 Replace the enclosure lid 16 Turn on the WhisperGen fuel valve The WhisperGen may now be started as required The old evaporator can be returned to your authorised WhisperGen service agent for servicing The evaporator should be s...

Page 80: ... the Main Menu on the control panel follow the first two steps of the procedure outlined in the section entitled Stopping the WhisperGen Setting the maximum run time 3 Press to scroll down to Installation Menu 4 Press to display the first item on the installation menu heat exchanger nozzle bleed If the exhaust heat exchanger becomes blocked the performance of the WhisperGen will decrease R FAULT A...

Page 81: ...select ON then press to begin flushing the exhaust heat exchanger Flushing will continue for 10 seconds R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Hx Nozzle Bleed R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Hx Nozzle Bleed ON ...

Page 82: ...can also let the default display re appear automatically by allowing a few minutes of inactivity on the control panel The WhisperGen may now be started as required R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Hx Nozzle Bleed OFF R FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START WTL0006 Battery Watts 563 ...

Page 83: ... Likely cause Low gas pressure and or burner seal has failed Recommended Action Attempt to restart contact an authorised WhisperGen service agent if problem reoccurs 4 Block overtemp Likely cause Insufficient cooling of the engine block Recommended Action Check coolant level Check for obstructions in coolant and seawater circuits Allow engine to cool and restart 6 Heatsink overtemp Likely cause Ex...

Page 84: ...attery bank and terminals If restarting fails check the batteries Replace faulty batteries and restart 19 High batt volts Likely cause Battery higher than 18 or 36 volts Recommended Action Check condition of battery bank and terminals 20 Bus not charged Likely cause Fault in electronics assembly or in battery bank voltage sensing wires Recommended Action Attempt to restart contact an authorised Wh...

Page 85: ...n Recommended Action Attempt to restart contact an authorised WhisperGen service agent if problem reoccurs 52 Fuel supply fail Likely cause Abnormal electrical condition Recommended Action Attempt to restart contact an authorised WhisperGen service agent if problem reoccurs 54 Flame sense fail See 46 56 O2 sensor fail Likely cause Oxygen sensor signal not within expected range Recommended Action C...

Page 86: ...l condition Recommended Action Attempt Restart contact an authorised WhisperGen service agent if problem reoccurs 74 Low engine power Likely cause Low power output possibly due to low gas pressure Low fuel flow Recommended Action Check fuel level fuel valve and fuel filter Check exhaust for blockage Flush heat exchanger Restart if problem reoccurs contact an authorised WhisperGen service agent 76 ...

Page 87: ...connected to the battery bank Restart 90 Clamp control flt Likely cause WhisperGen unable to maintain correct battery charging voltage Recommended Action Attempt to restart contact an authorised WhisperGen service agent if problem reoccurs 92 ParChg V too high Likely cause WhisperGen operating voltage has gone too high in an effort to avoid conflict with a parallel charger Recommended Action Check...

Page 88: ...cable 135 Likely cause Low battery bank voltage Recommended Action Check battery bank connections and battery bank voltage sensing wires Set a higher value for Max Run Hours and or turn Auto charge option ON 182 Likely cause Excessive voltage drop in cabling to battery bank Recommended Action Check battery bank connections and cables 183 Likely cause Battery bank temperature is high Recommended Ac...

Page 89: ...extreme electrostatic interference may cause the WhisperGen to become unresponsive to key presses on the control panel If this happens the WhisperGen electronics hardware should be reset as soon as possible to ensure that the battery bank is kept charged To reset the WhisperGen electronics hardware 1 Remove the enclosure lid When performing trouble shooting tasks on the WhisperGen refer to the app...

Page 90: ...e to key presses on the control panel If the control panel display was completely blank it may be that the fuse was blown In such a case check the fuse and if it has blown replace it with a new one 5 Replace the electronics enclosure cover and fasten the four screws 6 Replace the enclosure lid FUEL OFF ON 2 WTL0052 Electronics Enclosure Cover WTL0053 32A 15 3 5 10 3 Ensure that the replacement fus...

Page 91: ...ed to your authorised service agent within 14 days of the commissioning date Commissioning Engine Serial No Software Version Commission Date Commission Date Customer s Address Heat Manage Temp Setpoint Auto charge Ext Control Ext Cont Mode Max Run Hours Battery Capacity Max Batt Disch Tail Current Absorption Voltage Float Voltage Time Above 14V SelfDisch Mth Hour Meter Of Starts Agent s Stamp Othe...

Page 92: ... 14 days of the commissioning date Engine Serial No Software Version Commission Date Commission Date Customer s Address Heat Manage Temp Setpoint Auto charge Ext Control Ext Cont Mode Max Run Hours Battery Capacity Max Batt Disch Tail Current Absorption Voltage Float Voltage Time Above 14V SelfDisch Mth Hour Meter Of Starts Agent s Stamp Other Remarks ...

Page 93: ...R 88 Servicing Date Hours Description of Work Done Agent s Stamp DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading ...

Page 94: ...R 89 Date Hours Description of Work Done Agent s Stamp DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading DD MM YY Hour Meter Reading ...

Page 95: ...1 Safety of machinery basic concepts general principles for design basic terminology methodology EN292 2 A2 1997 Basic concepts general principles for design technical principles and specifications EN294 A2 1993 Safety of machinery safety distances to prevent danger zones being reached by upper limbs EN563 A1 1995 Safety of machinery temperatures of touchable surfaces ergonomics data to establish ...

Page 96: ...Section 3 radiated radio frequency electromagnetic field immunity test IEC 61000 4 4 1995 EMC Part 4 testing and measurement techniques Section 4 electrical fast transient burst immunity test basic EMC publication IEC 61000 4 5 1995 EMC Part 4 testing and measurement techniques Section 5 surge immunity test IEC 61000 4 6 1996 EMC Part 4 testing and measurement techniques Section 6 immunity to cond...

Page 97: ... 82 Current shunt 3 4 5 60 Displaying parameter settings 41 Earthing strap 8 9 EC conformity 90 Editing parameter settings 43 Electronics enclosure 8 9 64 82 Emergency stopping 21 Enclosure 8 9 Error codes 78 Evaporator 62 72 Exhaust heat exchanger 8 9 External control 25 Fault 32 78 Fault clearing 78 Fault codes 78 Fault correcting 78 Flame ionisation detector FID 8 9 67 Float charging 27 Flushin...

Page 98: ...g 62 Replacing oxygen sensor 70 Resetting control panel 81 Resetting electronics hardware 81 Safety precautions 11 Schedule for maintenance 45 46 Seawater pump 3 5 56 Specifications 6 7 Starting WhisperGen 18 19 Stirling cycle engine 2 Stopping WhisperGen 20 Summary of options 16 Summary of parts 8 9 System parameters 37 Temperature of coolant 30 Troubleshooting 78 Warning 32 82 Warning clearing 3...

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