Whisper Tech WhisperGen 3000 Series Installation And Commissioning Manual Download

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Personal Power Station

NSTALLATION

OMMISSIONING

ANUAL

Model:

PPS16

3000 and 7000 series

Configurations: 12V

24V

Diesel

Kerosene

Marine

Land

based

Summary of Contents for WhisperGen 3000 Series

Page 1: ...Personal Power Station INSTALLATION AND COMMISSIONING MANUAL Model PPS16 3000 and 7000 series Configurations 12V 24V Diesel Kerosene Marine Land based ...

Page 2: ...pressed or implied in this publication refer to warranties provided by authorised WhisperGen agents Warranty for proprietary parts shall be limited to those warranties extended by the supplier of those parts In no event shall Whisper Tech Ltd be liable to anyone for special collateral incidental or consequential damages in connection with or arising out of purchase or use of Whisper Tech products ...

Page 3: ...it 6 The secondary coolant circuit 6 Plumbing the primary coolant circuit 9 Plumbing the secondary coolant circuit marine systems 10 7 Setting up the battery and control system 11 Mounting the control panel 12 Connecting the battery 14 Control system connection points 15 8 Filling and bleeding the coolant circuits 17 9 Setting up combined heating and battery charging 19 Setting up hot water heatin...

Page 4: ...onitoring the WhisperGen using the control panel 29 16 Monitoring the WhisperGen using a computer 30 17 Running the WhisperGen for the first time 31 18 Heat dump test 32 19 User selectable function testing 33 20 Full power operating parameters 34 21 Completing commissioning and filling out the checklist 35 Appendix A Recommended components for the coolant circuits Appendix B Battery specifications...

Page 5: ...circuit series 7 Figure 3 Primary coolant circuit parallel 8 Figure 4 Plumbing the secondary coolant circuit marine systems 10 Figure 5 Setting up the battery 11 Figure 6 The control panel 13 Figure 7 Wiring diagram 16 Figure 8 Fuel pump and fuel line installation 22 Figure 9 Exhaust piping for marine and land based systems 25 Figure 10 Micromon MO screen 31 ...

Page 6: ... the PPS16 User s Manual Checklists for Installation and Commissioning of the WhisperGen are included in this manual to help ensure all services are properly connected before starting the WhisperGen and that the WhisperGen is operating correctly Fuel This manual applies to WhisperGen PPS16s which use diesel or kerosene The WhisperGen PPS16 burner and software are fuel specific Do not run a diesel ...

Page 7: ...e WhisperGen as per the instruction manual complete the installation checklist in full For checkpoints which are not applicable for this installation enter n a send a copy of the installation checklist to your authorized WhisperGen agent WhisperGen Engine Serial number Date of installation Installer Full name Address Phone Fax E Mail Owner Name Address Phone Fax E Mail Address of installation or h...

Page 8: ...ion pack are complete and on site 1 The WhisperGen is mounted in a position which is clean and dry and with sufficient ventilation 1 The WhisperGen is securely bolted in position 4 The WhisperGen is pressurised with nitrogen gas to 22 24 bar cold 25 C Plumbing the coolant circuits 5 The exhaust heat exchanger is fitted and bolted to the burner 6 The primary coolant circuit is plumbed using tubing ...

Page 9: ...nel is mounted in a dry position and the communication cable is connected 11 All connections from power sources and loads except the battery are to the battery side of the WhisperGen isolating switch 11 All connections from power sources and loads except the battery are to the non battery side of the current shunt 11 and APP B and C A deep cycle lead acid or gel battery with a minimum capacity of ...

Page 10: ...rate of 4 litres per minute 18 The secondary coolant circuit has no leaks Setting up the fuel system 20 For marine installations the fuel line installation where applicable complies with the Recreational Craft Directive 94 25 EC and marine regulations 20 The fuel line has an inside diameter of between 2 5mm and 3 5 mm and is a maximum of 8m in length 20 The fuel pump is mounted in an upright posit...

Page 11: ...ope of at least 10 degrees relative to the horizon will not be submerged at any time is not connected to any other outlets 34 The exhaust system is self draining of condensate under all conditions and condensate drains run from all points in the exhaust where condensate is likely to be trapped use a drain tube with a minimum inside diameter of 10mm and have air traps fitted 35 Fresh water at 1 5 t...

Page 12: ...acking the WhisperGen Removal of the pallet base is optional See this page Mounting the WhisperGen To unpack the WhisperGen 1 Unscrew the screws around the bottom of the crate 2 Carefully lift the cover vertically from the WhisperGen 3 Unpack the spare parts and installation pack from beside the WhisperGen 3 Mounting the WhisperGen See Figure 1 Minimum Clearances Services and Mounting bolts layout...

Page 13: ...hisperGen No Size 1 BSPP Female 2 BSPP Male 3 1 BSPP Female 4 13mm OD VIEW B VIEW A SECONDARY COOLING WATER OUT PRIMARY HEATING WATER IN PRIMARY HEATING WATER OUT SECONDARY COOLING WATER IN SECONDARY COOLING WATER IN PRIMARY HEATING WATER IN CONDENSATE OUT EXHAUST FRESH WATER IN BATT BATT FUEL DATA CABLES DATA CABLES 800mm minimum clearance 550mm minimum clearance 1 1 1 2 3 1 5 5 Marine only Marin...

Page 14: ...WhisperGen PPS16 Installation and Commissioning Manual Rev 080801 3 5 BSPP Female VIEW B BACK AIR BOX L C MOUNTING HOLE 4 OFF AIR INTAKE SLOT 170mm minimum clearance 650mm minimum clearance ...

Page 15: ...ne through a bottle mounted pressure regulator not supplied Warning The WhisperGen must be depressurised before transporting by aircraft The WhisperGen is pressurised with nitrogen gas To pressurise the WhisperGen 1 Attach the filler hose to the filling valve The filler hose is available from authorised WhisperGen agents 2 Attach the filler hose to the Nitrogen bottle hose not supplied using the s...

Page 16: ...burner during shipping To fit the exhaust heat exchanger 1 Unbolt and remove the clamp holding the exhaust heat exchanger to the enclosure base 2 Refit the bolt to the exhaust heat exchanger 3 Fit the supplied gasket between the exhaust heat exchanger and the burner 4 Firmly bolt the exhaust heat exchanger to the burner using the supplied nuts and washers ...

Page 17: ...ding in 7 can be either series or parallel Primary coolant circuits for WhisperGens with a manufacturing number ending in 6 shall always be in series with the pump A series circuit see Figure 3 Primary coolant circuit series is the preferred option because it ensures that primary coolant is always flowing through all parts of the circuit and it is self bleeding of air A parallel circuit see Figure...

Page 18: ...onal Water Heater optional Hot Water Cylinder optional Radiator with Heat Exchanger optional Radiator with by pass Thermostat optional Self Bleeding Header Tank with pressure relief Coolant Circulation Pump 100mm min 1m per 20 litres 300mm max Fan Heater optional FU EL External fan radiator Land based systems only ...

Page 19: ...onvection radiators with by pass thermostat optional Header Tank as high as possible Coolant Circulation Pump 100mm min 1m per 20 litres Fan heater with thermostat optional Air bleed valves installed at all high points 15mm inside diameter 22mm inside diameter 300mm max FU EL External fan radiator Land based systems only Must be in series ...

Page 20: ...e mounted directly below the coolant tank For series circuits a self bleeding header tank shall be installed at the highest point in the circuit The volume of the header tank shall be at least 5 of the total volume of coolant in the circuit This will allow for thermal expansion of the coolant Allow approximately 2 litres for the WhisperGen the distance between the self bleeding header tank and the...

Page 21: ...be connected to the inlet or outlet of another system Warning The inlet and the seawater pump shall be under the water line by a minimum of 200mm at all times Warning The inlet and outlet for the secondary coolant circuit shall be at least 2 metres apart Figure 4 Plumbing the secondary coolant circuit marine systems 200mm min Seawater Level Seawater Pump 750mm max FUEL BATT PRIMARY HEATING WATER I...

Page 22: ... connections from power sources and loads except the battery shall be made to the non battery side of the current shunt Figure 5 Setting up the battery note 1 The conductor shall have a cross sectional area of 1mm or if it is in a multi conductor sheath a cross sectional area of 75mm Battery Current shunt To WhisperGen Battery Terminal using 35mm wire To loads and other chargers To WhisperGen Curr...

Page 23: ...anel 3 Cut a rectangular hole 127mm wide x 114mm high for mounting the control panel 4 Use the clamp to secure the control panel in position 5 Connect the communication cable to the back of the control panel and run the wire back to the WhisperGen Figure 6 The control panel cut out dimensions FAULT AUTOCHARGE HEAT MANAGE STOP EXT CONTROL STOPPING START STANDBY STARTING RUNNING R Mounting Panel Mou...

Page 24: ...erminal to the current shunt which is supplied with the WhisperGen This allows the WhisperGen to monitor all charge and discharge current Do not make any other connections to the battery negative terminal or the battery side of the current shunt 3 Connect the battery sense wiring loom from terminals 7 to 11 connect the current shunt sense wire to terminal 7 connect the current shunt sense wire to ...

Page 25: ...ny other auxiliary equipment which is required to be switched by the WhisperGen Auxiliary power is available only when the WhisperGen is starting running or stopping The Auxiliary DC output shall be connected to terminals 14 and terminal 15 See Figure 8 Wiring diagram 7 3 3 Secondary Coolant Pump Warning Do not use relays in this circuit A DC PWM output from the WhisperGen enables the WhisperGen t...

Page 26: ...EXT Digital Out output terminals are 3 and 4 of the wiring block See Figure 8 Wiring diagram 7 3 6 External Temperature These terminals are not used They are 1 and 2 of the wiring block 7 3 7 Fuel Pump WARNING Only use the fuel pump supplied with the WhisperGen The fuel pump is a solenoid operated piston pump The speed of operation of the fuel pump is controlled by the WhisperGen microprocessor Th...

Page 27: ...WITCH THERMAL AMBIENT INTERNAL FUSE THERMAL EXHAUST HX RS485B RS485A RS232 BK BK BK BU BU PK BURNER SHELL EARTH STUD GLOWPLUG BK ENGINE MOUNT STUD OXYGEN SENSOR GN BK VI EXTERNAL EQUIPMENT CYLINDER TEMP SENSOR 100 C 100 C 600A 50mV 125A 30V EXT DIG OUT BK EXT DIG OUT OG EXT TEMP GY EXT TEMP VT TEMPERATURE SENSOR WH OR WH GR RD VT BK GY WH EXT DIGITAL OUT EXT TEMP EXT TEMP RD BK BN BU BK BU PWM BN ...

Page 28: ... cut on the mounting frame This valve must be closed at all times To bleed the primary coolant circuit 1 Fill the primary coolant circuit header tank with coolant 2 With the header tank full slowly unscrew the small bleed valve which is fitted to the top left hand side of the WhisperGen exhaust heat exchanger and any other bleed valves fitted to the circuit 3 Leave the bleed valve s open until the...

Page 29: ...u 3 Press to display the first item on the Installation Menu 4 Select Coolant Bleed 2 5 Press to begin editing the coolant bleed setting 6 Press to turn the Coolant Bleed 2 function to On 7 Check that the pump is priming and that seawater is flowing from the outlet 8 Check that the secondary coolant circuit has a minimum flow rate of 4 litres per minute 9 Check the secondary coolant circuit for le...

Page 30: ...he thermostat will open and turn the WhisperGen off 9 2 Setting up space heaters The heat output kW rating of most commercially available space heaters is rated with a room temperature of 20 C and a surface temperature coolant temperature of 80 C The maximum coolant temperature setting for the WhisperGen is 70 C To ensure that the full heat capacity from the WhisperGen can be used the size heat ou...

Page 31: ...aximum of 200mm Warning For marine installations the fuel system installation where applicable shall comply with the Recreational Craft Directive 94 25 EC issued by the Council of the European Community Warning Bleeding the fuel system will cause water pumps and fans to start Ensure pumps and coolant circuits are installed and bled before bleeding the fuel system If the fuel line is connected to a...

Page 32: ...m 1 Make sure that all fuel fittings are tight and not leaking Pressure test the fuel line from the fuel tank to the WhisperGen to 1 bar and check for leaks 2 Undo the fuel line from the evaporator on top of the burner Direct any diesel which comes out of the fuel line into a container 3 Turn on the fuel tap at the fuel tank and at the bottom front of the WhisperGen 4 On the control panel access t...

Page 33: ...al Rev 080801 22 Figure 8 Fuel pump and fuel line installation Fuel tank FUEL BATT PRIMARY HEATING WATER IN WATER OUT WATER IN Fuel pump Fuel filter 200mm max 1 25m max 2m max Back of WhisperGen Fuel tank The fuel line shall be a maximum of 8m in length ...

Page 34: ...aust pipe shall always have a slope of at least 10 relative to the horizon Momentary changes of slope to less than 10 relative to the horizon caused by a boat going over a wave or swell are acceptable See Figure 10 Exhaust piping for marine use Warning The exhaust back pressure measured at the WhisperGen exhaust port shall not exceed 7mm H 0 with Exhaust Temp greater than 400 C when the Air is at ...

Page 35: ...gth of straight walled exhaust pipe m Maximum length of corrugated walled exhaust pipe m 32 4 2 5 40 6 4 45 8 6 50 10 8 11 1 Fresh water flushing of the exhaust heat exchanger The exhaust heat exchanger is flushed with fresh water each time it is started to prevent water soluble deposit build up from the fuel This is done with a spray nozzle at the top of the exhaust heat exchanger The flushing us...

Page 36: ...port the exhaust will be submerged Port Starboard When the boat heels to starboard condensate will form at the low point Port WhisperGen WhisperGen To Waste Water Piping Unacceptable Exhaust Piping At Least 10 Ideal Exhaust Piping WhisperGen To Waste Water Piping To Waste Water Piping To Waste Water Piping To Waste Water Piping Acceptable Exhaust Piping ...

Page 37: ...ceptable Exhaust Piping Low Points Not Drained WhisperGen Less Than 10 To Waste Water Piping Acceptable Exhaust Piping To Waste Water Piping WhisperGen Drained Low Points To Waste Water Piping WhisperGen At Least 10 To Waste Water Piping Ideal Exhaust Piping To Waste Water Piping WhisperGen At Least 10 To Waste Water Piping WhisperGen At Least 10 Air Trap Air Trap Acceptable Exhaust Piping To Wast...

Page 38: ...ioning checklist in full For checkpoints which are not applicable enter n a send a copy of the commissioning checklist to the authorised WhisperGen supplier WhisperGen PPS16 Commissioning checklist WhisperGen Engine Serial number Date of commissioning Commissioner Full name Address Phone Fax E Mail Owner Name Address Phone Fax E Mail Location of WhisperGen or home shipyard of boat Name Address Pho...

Page 39: ...rom battery 32 The difference between the Battery Volts and the Bus Voltage is not more than 0 20V with the glowplug on 32 First StartFuel value 32 Additional heater is functioning 32 Time for flame to register after fuel is turned on seconds 32 FID reading at end of stabilising period 33 O2 Value at the end of the stabilising period 33 Maximum O2 Ave Error reading during heat up 33 Gross Watts 5 ...

Page 40: ...14 3 for 12V systems and 27 4 and 28 6 for 24V systems Battery Volts Battery Amps Battery Amp hrs Battery Watts Gross Watts Runtime Min Hour Meter of Starts Alt Current Air Bus Voltage Coolant Temp Clamp Current Clamp Voltage Exhaust Temp FID Current uA Fuel Cut Off Fuel Metering Fuel Frequency O2 Value O2 Ave Error Software Ver Nitrogen gas pressure reading NumFaults Battery Settings In Hidden Se...

Page 41: ...ble Settings Details Complete LCD display contrast setting OK LCD display back light setting OK Heat manage set to Temp setpoint set to Auto charge set to Ext Control set to Ext Control Mode set to Max Run Hhours set to Enable Starts set to Second StartFuel1 value Name and signature of commissioner ...

Page 42: ...ontrol Mode Max Run Hours 13 Battery settings Warning the recommendations of the battery manufacturer should be followed Battery settings are made in the hidden Service Menu To access the hidden menu 1 Select the Main Menu on the control panel 2 Press v until the control panel displays End of menus Press UP or 3 Press v vv vvv Authorised service personnel only is displayed on the control panel 4 U...

Page 43: ... setting is 14 4V for 12V systems and 28 8V for 24V systems This is usually adequate for lead acid or gel batteries Float Voltage Warning The Float Voltage is specific to the battery Battery manufacturer s recommendations shall be followed This is the voltage which the battery is held at if the WhisperGen continues running after the battery has been defined by the WhisperGen as fully charged The d...

Page 44: ...Installation section of this manual 15 Monitoring the WhisperGen using the Control Panel Warning If Auto restart is set to 0 the WhisperGen may attempt to restart automatically After a fault See the WhisperGen User s Manual for control panel operation The WhisperGen control system monitors the starting and running phase of the WhisperGen by checking the values given by the sensors If the microproc...

Page 45: ...l variables in the Extra Info Menu to be viewed on screen at the same time instead of one at a time on the control panel the recording of a log file detailing the readings of the WhisperGen sensors This is useful for fault solving Micromon MO software will run on a personal computer which is a minimum of an IBM 386 or compatible To install the Micromon MO software follow the instructions in the Do...

Page 46: ... is a maximum of 0 20 volts greater than the Bus voltage With the glow plug on the load on a 12 volt battery should be approximately 35 amps The load on a 24V battery should be approximately 18 amps 9 Press the stop button for one second The WhisperGen will shut down 10 Select the Installation Menu on the control panel and select the following settings Enable Starts shall be set to 2 Heat Manage s...

Page 47: ... 18 Check that the Gross Watts rises to a minimum of 200W five seconds after cranking and a minimum of 500W five minutes after cranking 18 Heat dump test To check the cooling capacity of the heat dump circuit 1 Disconnect or turn off heat removal devices except the marine heat exchanger or the external fan radiator If it is not possible to disconnect or by pass a boiler ensure that the water in th...

Page 48: ...rGen runs for a minimum of one hour each time it is started by an Ext Control This prevents the WhisperGen stopping and starting every 10 minutes if it is fitted with a thermostat To check the Auto charge operation without having to discharge the battery 35 for Auto start 1 Make sure the WhisperGen is in Standby mode 2 Set Battery Capacity to 100 Battery capacity is set in the hidden Service Menu ...

Page 49: ...un at full power Bulk charge will be displayed on the control panel 4 Check that Gross Watts is greater than 750 and that Fuel Frequency is less than 14 50 when Runtime minimum is greater than 45 Bulk charge is displayed on the control panel Coolant temp is a minimum of 67 and a maximum of 72 Coolant temp is adjusted with the Temp Setpoint option Battery Volts are a minimum of 13 8 and a maximum o...

Page 50: ... Start the WhisperGen and record the second StartFuel1 value at the end of the commissioning checklist There will be a slight difference between the two values 2 Complete the Commissioning Details section at the back of the User s Manual 3 Complete the Commissioning Checklist in the Installation and Commissioning manual and return it to the Whisper Tech Limited and the distributor ...

Page 51: ...nsumption Pump type Part number CM10P7 1 12V 10 24502 03 CM30P7 1 24V 10 24504 04 Webasto Pump This can be used as a primary and or secondary pump Fabr Nr 49180 Identy Nr 35853D 24V 12V is also available Alternative Secondary circuit pump marine system Whale Gulper 22 Use this pump in the secondary coolant circuit where the pump is not always below water level It is a membrane pump which is self p...

Page 52: ...Gen Contaminated circuits should be fitted with sludge traps upstream of the WhisperGen Potable water only should be used in the primary circuit to cool the WhisperGen A corrosion inhibitor must be added APPENDIX B Battery specification A deep cycle lead acid or gel battery with a minimum capacity of 200 ampere hours at 12V or 24V shall be used The battery cable size shall be a minimum of 35mm The...

Page 53: ...tallation and Commissioning Manual Rev 080801 38 APPENDIX C Recommendation for circuit breaker The recommended circuit breaker is Blue Seas type 7103 125A 30V or similar A 200 amp fuse can be used with an isolating switch ...

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Whisper Tech WhisperGen 3000 Series, Installation And Commissioning Manual

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Summary of Contents for WhisperGen 3000 Series

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