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Replacing the Evaporator

Maintenance

60

Replacing the Evaporator

Overview

Replace the evaporator if error codes 58, 59, 60, 61, or 62 occur
repetitively. In general, you should check and/or replace the FID and
oxygen sensor before deciding to replace the evaporator. Only replace the
evaporator after replacing the evaporator wick to reduce your maintenance
costs. See the previous procedure to replace this.

It is advisable to keep a spare evaporator with the

WhisperGen

TM

at all times.

Procedure

To replace the evaporator:

1. Remove the FID.

2. Remove the glow plug.

3. Turn off the WhisperGen

TM

fuel valve.

FUEL

OFF

ON

Personal Power Station

4. Unscrew the fuel line fitting on top of the burner.

2

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Summary of Contents for PPS16-12MD

Page 1: ...user s manual Part Number WP 5012 001 01 ...

Page 2: ......

Page 3: ...wer Station and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited Title User s Manual Models PPS16 12MD PPS16 24MD Part No WP 5012 001 01 Application WhisperGen PPS16 12MD Diesel fired 12 V DC output Marine WhisperGen PPS16 24MD Diesel fired 24 V DC output Marine WhisperGen is designed and manufactured by Whisper Tech 224 Armagh St P O Box 13 705 Christchurch New ...

Page 4: ......

Page 5: ...manual without necessarily notifying its users Variations in installation and operating conditions may affect the WhisperGen TM s performance Whisper Tech has no control over each installation s unique operating environment Hence Whisper Tech makes no representations or warranties concerning the performance of the WhisperGen TM under the actual operating conditions prevailing at the installation A...

Page 6: ... Clearing Faults and Warnings 28 Adjusting the LCD 30 Displaying System Information 31 Displaying Information 35 Editing Parameter Settings 36 Maintenance 37 Introduction 37 Scheduled service intervals and tasks 38 Removing the Enclosure Lid 39 Checking the Fuel 40 Bleeding the Fuel Line 41 Cleaning the Fuel Pump Filter 43 Checking the Coolant 45 Bleeding the Coolant Circuit 46 Checking Battery Ba...

Page 7: ...nual to highlight information that is critical to the safety of people and equipment and to the safe and correct operation of the WhisperGen TM An extreme hazard which may result in death or injury if proper precautions are not taken A reminder of safety practices or unsafe practices which could result in personal injury or damage to associated equipment A reminder of safety practices or unsafe pr...

Page 8: ......

Page 9: ...his manual must be permanently placed alongside the WhisperGen TM and maintained in a readable condition Check with your local authority about this requirement What It Does The WhisperGen TM PPS16 is a Personal Power Station that generates heat and electrical energy simultaneously The WhisperGen TM PPS16 is capable of charging and managing a lead acid battery bank to provide a DC electrical power ...

Page 10: ...y which can be used to charge a lead acid battery bank The nitrogen gas is heated by a continuous combustion burner and cooled by coolant circulating through engine cavities Heat transferred to the coolant can be used to heat domestic water cylinders and for space heating The burner consumes air and fuel The flow rate of air and fuel into the burner is optimised by a microcomputer This maximises c...

Page 11: ...cal Marine Application 9 1 7 8 2 3 4 5 6 Number Description 1 WhisperGen TM 2 Battery Bank 3 DC AC inverter 4 Standard domestic appliances 5 Hot water for domestic use 6 Space heating 7 Excess heat removal 8 12 or 24 V equipment 9 Cool exhaust vent ...

Page 12: ...om 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 control of an external heater to boost ...

Page 13: ...equires external coolant pump and seawater pump Exhaust temperature 80 C nominal 95 C maximum Cooling system extracts heat from exhaust Connections All connections provided on the rear 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 fittin...

Page 14: ...T CONTROL HEAT MANAGE STOPPING RUNNING STARTING STANDBY STOP START R R 1 7 8 9 2 3 4 5 6 10 Number Description 1 Fuel evaporator assembly 2 Air intake 3 Burner assembly 4 Exhaust heat exchanger 5 Lifting lug 6 Terminal block 7 Electronics enclosure 8 Main enclosure cover 9 Fuel valve 10 User control panel ...

Page 15: ...icators The lights that indicate the status of the WhisperGen TM system STANDBY the WhisperGen TM is ready to start STARTING the WhisperGen TM is starting RUNNING the WhisperGen TM is operating STOPPING the WhisperGen TM 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 TM is enabled HEAT M...

Page 16: ...led and serviced by an authorised WhisperGen TM service agent Incorrect installation or servicing can damage the WhisperGen TM and property cause personal injury and or void the warranty Always heed warning signs on the WhisperGen TM The engine contains high pressure nitrogen and some internal surfaces are hot F U E L OF F ON Critical Applications Other Supply WTL0016 Personal P ow er Stati on Nev...

Page 17: ...ed Never remove the burner earthing strap as this will cause the fuel line to act as the earthing path for the glow plug The fuel could heat up causing a malfunction or a fire Do not use fuels other than the specified class of fuel as this may damage the WhisperGen TM and or cause a fire Air bubbles present in the fuel line can cause the WhisperGen TM to malfunction Bleed the fuel line after filli...

Page 18: ...ant mixture Using an incorrect type of coolant fluid can cause serious corrosion in the WhisperGen TM Ensure that fuel and coolant used on the WhisperGen TM are clean and free of particulate contaminants Foreign particles can obstruct fuel coolant passages resulting in a malfunction or damage to the WhisperGen TM FUEL OFF ON Personal Power Station 2 During normal operation of the WhisperGen TM the...

Page 19: ...tion Do not expose the WhisperGen TM to large physical impacts FUEL OFF ON Personal Power Station Do not expose the WhisperGen TM to excessive vibration FUEL OFF ON Personal Pow er Station Do not expose the WhisperGen TM to extreme temperatures The ambient temperature should not exceed 40 C or fall below 10 C FUEL OFF ON Personal Power Station Do not install operate or store the WhisperGen TM in a...

Page 20: ...tion through the WhisperGen TM may be disrupted FUEL OFF ON Personal Pow er Station Do not drill holes in the enclosure Air circulation through the WhisperGen TM may be disrupted Do not modify the piping for the fuel exhaust and cooling systems of the WhisperGen TM without first consulting an authorised WhisperGen TM agent FUEL OFF ON Person al Pow er Station Isolate the WhisperGen TM from the bat...

Page 21: ... only If in doubt call your authorised WhisperGen TM service agent FUEL OFF ON Personal Pow er Station In some countries it is a requirement that a maintained fire extinguisher be permanently located alongside an installed WhisperGen TM Consult your local authority for information FUEL OFF ON Personal Pow er Station In case of fire use a carbon dioxide or dry powder extinguisher do not use water ...

Page 22: ...ting Options Depending on the options selected the WhisperGen TM may stop running before or after the battery bank is charged as shown in the table below Heat Manage ON Heat Manage OFF WhisperGen TM starting method Max Run Hours 25 Max Run Hours 25 Max Run Hours 25 Max Run Hours 25 Manual start Remote switch start with Ext Cont Mode set to 1 Continues running until stopped by the user Remote switc...

Page 23: ...Control Ext Control 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 ...

Page 24: ...it If the fault indicator is constantly lit you will need to clear the fault see section entitled Clearing Faults and Warnings If nothing is displayed on the control panel check that the WhisperGen TM is connected to the battery bank and that the 3A fuse F2 position as marked on PCB is not blown R 2 Turn on the fuel valve FUEL OFF ON Personal Power Station TM ...

Page 25: ...ent Every time the WhisperGen TM is operated the battery bank is charged Once the battery bank is fully charged the WhisperGen TM 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 TM is in Heat Manage mode the WhisperGen TM will continue to run for as long as there is a heat demand If ...

Page 26: ...perGen TM goes through a shutdown sequence lasting two to five minutes during which the engine is cooled down When the WhisperGen TM has fully stopped the STANDBY indicator lights up and the control panel displays WhisperGen The WhisperGen TM must be in the standby mode before it can be started again If a remote switch has been installed to control the WhisperGen TM you can also stop the WhisperGe...

Page 27: ...en TM FUEL OFF ON Personal Power Station The flame in the WhisperGen TM burner will be extinguished within a few seconds The fuel cut off will be registered as a fault and the WhisperGen TM will stop The fault will need to be cleared see section entitled Clearing Faults and Warnings before the WhisperGen TM can be started again The WhisperGen TM will attempt to re start if auto restart is enabled ...

Page 28: ...continuously until the battery bank is fully charged Max Run Hours 21 Optional press Left Arrow repeatedly to return to the default display The default display will re appear automatically after a few minutes of inactivity on the control panel If the Max Run Hours setting is less than 25 the WhisperGen TM will automatically stop when the Max Run Hours set value is reached even if the battery bank ...

Page 29: ...the first item on the main menu the User Menu User Menu 3 Press Right Arrow to display the first item on the User Menu Heat Manage 4 Press Down Arrow to scroll down to Ext Control Ext Control 5 Press Right Arrow to begin editing the external control setting 6 Press Up Arrow to select ON The EXT CONTROL indicator lights up R 7 Press Left Arrow to quit editing Ext Control 8 Press Down Arrow to scrol...

Page 30: ...M is started while the remote switch is closed the WhisperGen TM stops when the remote switch is opened Optional press Left Arrow 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 The effect of starting or stopping the WhisperGen TM using a remote switch is similar to pressing START ...

Page 31: ...ging ceases and other battery charging settings are set during the commissioning of the WhisperGen TM These settings are set according to the needs of your particular application If you wish to change these settings contact your authorised WhisperGen TM agent During the commissioning of the WhisperGen TM some system parameters are set specifically for the particular battery bank that is being used...

Page 32: ...the User Menu Heat Manage 4 Press Down Arrow to scroll down to Auto charge Auto charge 5 Press Right Arrow to begin editing the auto charge setting 6 Press Up Arrow to select ON The AUTOCHARGE indicator lights up R Optional press Left Arrow repeatedly to return to the default display The default display re appears automatically after a few minutes of inactivity on the control panel With the Auto c...

Page 33: ... option OFF If the WhisperGen TM was started by the auto charge function the Max Run Hours setting does not affect the operating time of the WhisperGen TM Regardless of the Max Run Hours setting the WhisperGen TM will fully charge the battery bank before stopping For a summary on operating options see the Quick Reference in the User Manual Bulk charging the Battery Bank While the WhisperGen TM is ...

Page 34: ...eat Manage 4 Press Down Arrow to scroll down to Temp Setpoint Temp Setpoint 5 Press Right Arrow to begin editing the coolant temperature setting 6 Press Up Arrow or Down Arrow to select the coolant temperature The values shown on the control panel are in C Temp Setpoint 62 Optional press Left Arrow repeatedly to return to the default display You can also let the default display re appear automatic...

Page 35: ...menu the User Menu User Menu 3 Press Right Arrow to display the first item on the User Menu Heat Manage 4 Press Right Arrow to begin editing the heat management setting 5 Press Up Arrow to turn the Heat Manage option ON The HEAT MANAGE indicator lights up R Optional press Left Arrow repeatedly to return to the default display You can also let the default display re appear automatically by allowing...

Page 36: ...trol panel The WhisperGen TM shuts down automatically Upon detecting a fault the WhisperGen TM will shut down and then automatically clear the fault and attempt to restart By default the WhisperGen TM will attempt to restart once If you wish to change this setting contact your authorised WhisperGen TM agent Error messages associated with faults from which the WhisperGen TM cannot recover by itself...

Page 37: ...started any warning present is automatically cleared To manually clear a warning 1 Access the main menu on the control panel Access the default display on the control panel by pressing Left Arrow repeatedly Battery Watts 2 Press Right Arrow to display the first item on the main menu the User Menu User Menu 3 Press Down Arrow to scroll down to Fault Warning Menu Fault Warning Menu 4 Press Right Arr...

Page 38: ...trast settings are retained for up to approximately one month after the disconnection Adjusting the Backlight The LCD has a backlight which makes the LCD more visible in dark environments The backlighting can be manually adjusted To adjust the LCD backlight Hold down Left Arrow and press the Right Arrow repeatedly until the desired level of backlighting is achieved Three levels of backlighting are...

Page 39: ...o 100Ah Battery Watts The quantity of electrical power in Watts supplied to the battery bank Positive values indicate charging and negative values indicate discharging 7000 to 1000 Watts Gross Watts The gross electrical power in Watts from the WhisperGen TM 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...

Page 40: ...rates see section entitled Setting the maximum run time 1 to 24 hours or 25 hours for continuous operation default Fault Warning Menu 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...

Page 41: ...g between the FID flame ionisation detector electrode and the burner shell A large current indicates a good stable flame in the burner and correct FID operation 0 to 10µA Fuel Cut Off The position of the automatic fuel isolation valve located inside the WhisperGen TM It should be ON when the WhisperGen TM is operating ON or OFF Fuel Metering The operating state of the fuel pump It should be ON whe...

Page 42: ...ction see section entitled Bleeding the Fuel Line The water pumps may start when the fuel line is bled ON or OFF default Coolant 1 Bleed The coolant bleeding function see section entitled Bleeding the Coolant Circuit ON or OFF default Coolant 2 Bleed The seawater and coolant bleeding function see section 3 8 ON or OFF default Enable Starts The function that enables or disables WhisperGen starts du...

Page 43: ...s initially displayed pressing Left Arrow twice returns to the default display Battery Watts To display a menu at a lower level Press Right Arrow For example if Battery Volts a parameter in the default display is displayed initially then to display the main menu press Right Arrow once as shown User Menu To display a menu at a higher level Press Left Arrow For example if Alt Current is displayed in...

Page 44: ...uto charging setting then display Auto charge on the control panel by pressing Right Arrow twice followed by Down Arrow twice from the default display Auto charge 2 Press Right Arrow 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 displayed depending on the existing setting of Auto charge Auto charg...

Page 45: ... out maintenance the Enable Starts option in the Installation Menu should be set to 0 to prevent unintentional starts of the WhisperGen TM Reset to either 1 or 2 depending on the user setting requirement after maintenance has been completed For information on how to edit the settings refer to the section entitled Displaying System Information Editing Parameter Settings If service checks are not pe...

Page 46: ...for any exhaust gas leakage Service B Intermediate Service Interval What to check after each 1000 hours of use Service B Schedule 1 000 hours use 24 months since installed 3 000 hours use 72 months since installed 5 000 hours use 120 months since installed etc Carry out Service B tasks 13 19 after completing Service A tasks 1 12 first 13 Change the primary coolant and reverse flush the system 14 C...

Page 47: ...ings from the upper plastic hooks on both sides of the WhisperGen TM WTL0018 2 Carefully lift the enclosure lid WTL0019 Do not touch the surfaces that are labelled as hot and do not operate the WhisperGen TM without the enclosure lid on for more than 10 minutes as air circulation through the WhisperGen TM will be disrupted When replacing the lid hook it over the back of the enclosure base and swin...

Page 48: ...el heating oil petrol or aviation fuel Procedure To check the fuel level 1 Remove the fuel tank cap The fuel tank is located outside the WhisperGen TM and is typically within five metres of it 2 Ensure that the fuel level is adequate The fuel level must be higher than the fuel outlet point at all times WTL0020 Minimum Inadequate Outlet Outlet Fuel Fuel 3 Replenish fuel if necessary taking care not...

Page 49: ...ant and seawater pumps may start when the fuel line is bled To prevent unintentional starts of the WhisperGen TM heed the warning given at the beginning of this section Do not touch the surfaces that are labelled as hot Procedure To bleed the fuel line 1 Stop the WhisperGen TM and wait until the STANDBY indicator on the control panel is lit 2 Remove the enclosure lid and wait for the engine to coo...

Page 50: ...Press Up Arrow to select ON Fuel will be bled through in pulses for 60 minutes You can stop the fuel pump at any time by pressing v At least twice the volume of fuel in the entire fuel line connecting the fuel tank to the evaporator must be bled For example if the fuel line measures 3mm in inner diameter and 5m in length then 70ml of fuel must be bled Fuel Bleed ON 11 Optional press Left Arrow rep...

Page 51: ...ntly or if the power output is constantly low Procedure To clean the fuel filter 1 Turn off the fuel tank valve and the WhisperGen TM fuel valve Fuel Tank Fuel Tank Valve Auxiliary In line Filter Fuel Pump WTL0025 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 Fuel Pump WTL0026 4 Undo the cylindrical brass fitting WTL0027...

Page 52: ...brass fitting and secure 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 TM 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 Wh...

Page 53: ...g it Using an incorrect type of coolant can cause serious corrosion in the WhisperGen TM use only the recommended coolant Ensure that the coolant is free of particulate contaminants Foreign particles in the coolant can obstruct coolant passages in the engine resulting in damage to the WhisperGen TM Do not connect the boat s main engine cooling system to the same circuit as the WhisperGen TM as cas...

Page 54: ...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 Access the Main Menu on the control panel Access the default display on the control panel by pressing Left Arrow repeatedly Battery Watts 4 Press Right Arrow to display the first item on the main menu the User Menu User Menu 5 Press Down Arrow to scroll down to Installation...

Page 55: ...ing and then press Down Arrow to turn off the coolant pump Coolant 1 Bleed OFF 17 Optional press Left Arrow 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 18 Replace the enclosure lid The WhisperGen TM may now be started as required The seawater circuit may need to be bled if the ...

Page 56: ...nnections as shown below are intact and clean FUE L OFF ON Current Shunt Current Sensing Wires Power Cables Voltage Fuse White No assigned colour No assigned colour Green Black Violet Red Circuit Breaker Voltage Sensing Wires Temperature Sensor Battery Bank WTL0032 Personal Power Station 2 Check that the circuit breaker is closed 3 Replace the voltage fuse if it has blown 4 Check that the electric...

Page 57: ...sperGen TM at all times Glow plugs used on the WhisperGen TM should be obtained from authorised WhisperGen TM agents Procedure To replace the glow plug 1 Stop the WhisperGen TM 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 WTL0034 Evaporator Glow Plug Glow Plug...

Page 58: ...nsure of the cause of the fault contact your authorised WhisperGen TM service agent for assistance Ensure that the replacement fuse is of a similar type Ø0 25 x 1 25 inch or Ø6 35 x 31 75mm and of the correct current rating 2 00A It is advisable to keep spare fuses with the WhisperGen TM at all times Procedure To replace the battery bank voltage fuse 1 Unscrew the fuse holder FUEL OFF ON Voltage F...

Page 59: ...ional starts of the WhisperGen TM heed the warning given at the beginning of this section Do not touch surfaces that are labelled as hot Ensure that the replacement fuse is of a similar type and of the correct current rating It is advisable to keep spare fuses with the WhisperGen TM at all times Procedure To replace a fuse other than the battery bank voltage fuse 1 Stop the WhisperGen TM and wait ...

Page 60: ...llary Seawater Pump Coolant Pump Circuits Internal Coolant Pump Circuit Fuel Pump Fuel Shut off Valve Circuits Air Blower Oxygen Sensor Flushing Circuits Control Panel Microcomputer Circuits Glow Plug Circuit WTL0038 32A 15 3 5 10 3 5 Replace the faulty fuse 6 Replace the electronics enclosure cover and fasten the four screws 7 Replace the enclosure lid 8 Reconnect the WhisperGen TM to the battery...

Page 61: ...and wait for the engine to cool 3 Undo the screw on top of the FID and detach the wire WTL0039 Evaporator Glow Plug FID Evaporator FID 4 Undo the screw that secures the FID clip to the evaporator 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 tha...

Page 62: ...m no less than 8mm and no more than 10mm and put a second mark on the wire at the top level of the evaporator WTL0043 Evaporator Wire Second mark First mark 8 10 mm 10 Remove the wire from the evaporator and move the FID clip so that the distance from the clip to the electrode tip is the same as the distance from the second mark on the wire to the bottom tip of the wire To move the clip wedge it o...

Page 63: ...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 TM may now be started as required ...

Page 64: ...elled as hot Do not touch the sensing tip of the oxygen sensor as this will shorten its life span It is advisable to keep a spare oxygen sensor with the WhisperGen TM at all times Procedure To replace the oxygen sensor 1 Stop the WhisperGen TM 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 Detach the electrical connecto...

Page 65: ...osition on the oxygen sensor The ferrules should be distanced 60mm from the sensing tip of the oxygen sensor WTL0048 Do Not Touch Here 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 TM may now be started as required ...

Page 66: ...rator wick 1 Remove the FID Inspect the FID for wear or damage 2 Remove the glow plug Inspect the glow plug for wear or damage 3 Turn off the WhisperGen TM fuel valve 4 Unscrew the fuel line fitting on top of the burner 5 Undo the four screws on top of the evaporator with a 4mm allen key 6 Lift the evaporator out of the burner 7 Remove the evaporator gasket Replace it if it is not flexible or if i...

Page 67: ...he positioning of the evaporator as needed 15 Refit the glow plug Replace the glow plug if badly worn or damaged to ensure optimal running 16 Reconnect the fuel line to the evaporator Finger tighten the nut then tighten 3 4 turn using a spanner Ensure that there is no leakage 17 Refit the FID Carefully the procedure in this manual entitled Replacing the FID to ensure correct FID positioning for op...

Page 68: ...ace the evaporator Only replace the evaporator after replacing the evaporator wick to reduce your maintenance costs See the previous procedure to replace this It is advisable to keep a spare evaporator with the WhisperGen TM at all times Procedure To replace the evaporator 1 Remove the FID 2 Remove the glow plug 3 Turn off the WhisperGen TM fuel valve FUEL OFF ON Personal Power Station 4 Unscrew t...

Page 69: ...7 Place the evaporator gasket on the new evaporator ensuring that all the holes line up WTL0051 8 Insert the new evaporator with the gasket into the burner and secure the four screws 9 Check that the FID slides freely into the burner If necessary loosen the four evaporator screws and readjust the position of the evaporator before re tightening them 10 Refit the glow plug ...

Page 70: ...en turn only 12 Ensure that there are 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 TM fuel valve The WhisperGen TM may now be started as required The old evaporator can be returned to your authorised WhisperGen TM service agent for servicing ...

Page 71: ...fault display on the control panel by pressing Left Arrow repeatedly Battery Watts 3 Press Right Arrow to display the first item on the main menu the User Menu User Menu 4 Press Down Arrow to scroll down to Installation Menu Installation Menu 5 Press Right Arrow to display the first item on the installation menu 6 Press Down Arrow to scroll down to Hx Nozzle Bleed Hx Nozzle Bleed 7 Press Right Arr...

Page 72: ...ollowing the manufacturer s recommendations Follow the procedure entitled checking the coolant You must also disconnect and drain the fresh water supply systems to the WhisperGen TM and you must also ensure that the secondary system is drained of all raw water The fresh water is normally plumbed into the pressurised water supply to a fresh water connector on the WhisperGen TM Drain any water in th...

Page 73: ...umed Although a warning can be cleared without the physical cause being removed it is recommended that the cause be determined and removed at the earliest opportunity Refer to section entitled Clearing Faults and warnings for more information If you need assistance please contact your authorised WhisperGen TM service agent You should read and understand all safety precautions before operating or m...

Page 74: ...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 oxygen sensor When oxygen sensor faults arise If burner or flame faults occur despite FID replacement Replacing the evaporator See section Replacing the evaporator If burner ...

Page 75: ...ion of impeller or electrical fault Recommended Action Check connections and presence of any obstructions Restart 14 O2 sensor failure Likely cause Absence of normal signal from oxygen sensor or faulty oxygen sensor Recommended Action Check connections Replace the oxygen sensor if fault continues Restart 16 Fuse Daisy Ch fail Likely cause Electrical or thermal fuse blown or break in burner safety ...

Page 76: ...2 Fuel supply fail Likely cause Abnormal electrical condition Recommended Action Attempt to restart Contact an authorised WhisperGen TM service agent if the problem reoccurs 54 Flame sense fail See 46 56 O2 sensor fail Likely cause Oxygen sensor signal not within expected range Recommended Action Check connectors and restart Replace oxygen sensor if fault continues 58 Ignition failure Likely cause...

Page 77: ...Likely cause Battery bank temperature too high for safe charging Recommended Action Check battery bank connections and ventilate battery bank compartment Restart 84 Clamp failed off Likely cause Abnormal electrical condition possibly resulting in raised battery voltage Recommended Action Attempt to restart Contact an authorised WhisperGen TM service agent if the problem reoccurs 85 High batt volts...

Page 78: ...ning or engine is hot This could be the result of a bad contact between the WhisperGen TM and the control panel Recommended Action Fit a new 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 ...

Page 79: ...cating normal operation Battery Watts Resetting the Electronics Hardware Overview In some cases extreme electrostatic interference may cause the WhisperGen TM to become unresponsive to key presses on the control panel If this happens the WhisperGen TM electronics hardware should be reset as soon as possible to ensure that the battery bank is kept charged Do not touch the surfaces that are labelled...

Page 80: ... 3A WTL0053 32A 15 3 5 10 3 4 Check that the WhisperGen TM is responsive 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 ...

Page 81: ...services 73 Service Log Service Log 500 hour services Date Hours Description of Work Done Agent s Stamp DD MM YY 500 Hour Meter Reading DD MM YY 1500 Hour Meter Reading DD MM YY 2500 Hour Meter Reading DD MM YY 3500 Hour Meter Reading ...

Page 82: ...1000 hour services Service Log 74 Service Log 1000 hour services Date Hours Description of Work Done Agent s Stamp DD MM YY 1000 Hour Meter Reading DD MM YY 3000 Hour Meter Reading DD MM YY 5000 Hour Meter Reading ...

Page 83: ...Service Log 2000 hour services 75 Service Log 2000 hour services Date Hours Description of Work Done Agent s Stamp DD MM YY 2000 Hour Meter Reading DD MM YY 4000 Hour Meter Reading DD MM YY 6000 Hour Meter Reading ...

Page 84: ...he installation of the WhisperGen TM must comply with the Recreational Craft Directive 94 25 EC and the Amending Directive 2003 44 EC The Recreational Craft Directive harmonised standards relevant to the installation of the WhisperGen TM are ISO 7840 2004 Small craft Fire resistant fuel hoses ISO 9093 1 1994 Small craft Seacocks and through hull fittings metallic ISO 9093 2 2002 Small craft Seacoc...

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