Whisper Power W-SC3 User Manual Download

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USERS MANUAL FOR MOBILE APPLICATIONS

W-SC3

- 3000 RPM -

Mobile diesel generating set 230V / 50Hz

Digital Diesel Control

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

V1. January 2011

Art.nr. 40200309

Summary of Contents for W-SC3

Page 1: ...IONS W SC3 3000 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten The Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 January 2011 Art nr 40200309 ...

Page 2: ...ation 8 2 3 4 Accessories included in the standard delivery 8 2 4 Components 9 2 4 1 Main components to identify 9 2 4 2 Generator control panel 10 2 4 3 Remote control panel 10 2 5 Technical Information 10 2 5 1 AC alternator 10 2 5 2 Engine 10 2 5 3 Digital Diesel Control system 10 2 5 4 Battery charger 11 2 5 5 Alarms and shut down 11 2 5 6 Control 11 2 5 7 Remote control 11 2 5 8 Hour counter ...

Page 3: ... 1 Maintenance schedule 20 4 3 2 Putting out of service 20 5 TROUBLE SHOOTING 21 5 1 Alternator electrical faults 21 5 1 1 General 21 5 1 2 Trouble shooting table 21 5 2 Engine faults 22 5 2 1 General 22 5 2 2 Trouble shooting table 22 5 2 3 Warnings 25 5 2 4 Service address 25 5 3 Special procedures alternator 25 5 3 1 Residual voltage check excitation procedure 25 5 3 2 Testing rotary rectifier ...

Page 4: ... guarantees that this generating set has been built according to good workmanship according to the specifications in this manual and according to European Community safety regulations During production and prior to delivery all of our generating sets are tested and inspected The functioning of this generating set is subject to guarantee The period and conditions of this guarantee are laid down in ...

Page 5: ...ation manual then damage may occur and the generating set may not fulfil its specifications In all these cases the guarantee may become invalid Use original spares only 1 4 LIABILITY Whisper Power does not accept responsibility for damage injuries or casualties which are the result of operation of the generating set in specific conditions which brings dangers which could not be foreseen or could b...

Page 6: ... any doubt 2 INFORMATION 2 1 SAFETY 2 1 1 General When correctly installed and used in normal circumstances this generating set fulfils EC safety regulations This generating set could be part of an installation or could be used in a way that additional regulations of the EC or other authorities have to be taken into account Circumstances could make it also necessary to take additional measures Be ...

Page 7: ...parts and especially parts of the exhaust system If the generating set is unsafe fit danger notices and disconnect the battery positive lead so that it cannot be started until the condition is corrected Do not attempt to operate the generating set with a known unsafe condition Disconnect the battery positive lead prior to attempting any repairs or cleaning inside the enclosure Always consult the m...

Page 8: ... a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s sides The set is not self contained and is only operable after proper installation using additional accessories and installation ma...

Page 9: ...id fuel valve 20 Electric fuel lift pump 21 Cooling water pump 22 Oil pressure pump 23 Fuel pressure pump 24 Oil pressure switch 25 Oil sump pump 26 Exhaust connection 27 Fuel return 28 Oil filler cap oil level indicator 29 Control panel 30 Capacitor 31 Fuse 1 32 Fuse 2 33 Remote control cable 34 Stop solenoid 35 Oil strainer cover 36 Start button 37 Digital Diesel Control unit 38 RPM set screw 39...

Page 10: ...ffect of load switching to relieve the burden on the engine Further technical data on the design of the alternator can be found in drawings and diagrams in this manual The alternator is water cooled and the cooling liquid is cooled by a radiator 2 5 2 Engine The W SC3 generating set is based on the Kubota OC60 1 cylinder diesel engine The engine is indirectly injected The engine is oil cooled and ...

Page 11: ...the units Refer to installation instructions 2 5 8 Hour counter The remote control offers several timer functions that helps to schedule maintenance 2 5 9 Load indicator On the remote control the load will be indicated on the display and by the LED bar The load is measured by a current transformer on the alternator 2 5 10 Fuel specification The engine must only be used with diesel fuel oil which c...

Page 12: ... cooling liquid is not available clean fresh water could be used with an additive of anti freeze When using water with anti freeze the right mixture has to be calculated according to the information of the supplier of the anti freeze The cooling system is not pressurised 2 5 14 Technical data GENERAL Model W SC3 mobile RPM 3000 Alternator water cooled synchronous Engine Kubota diesel model OC60 Ja...

Page 13: ...2 DDC starter solenoid 4 yellow 2 5 mm2 LCP fuel lift pump 5 brown 1 5 mm2 LCP fuel lift pump 15 black 1 5 mm2 DDC LCD 5 grey 1 5 mm2 DDC oil pressure switch 6 purple 1 mm2 LCP oil pressure switch 6 purple black 1 mm2 DDC oil temperature switch 7 blue 1 mm2 LCP oil temperature switch 7 blue black 1 mm2 DDC exhaust temperature switch 8 blue green 1 mm2 LCP exhaust temperature switch 8 blue pink 1 m...

Page 14: ...INFORMATION 14 January 2011 W SC3 Mobile EN 2 5 16 DC wiring diagrams Fig 7 ...

Page 15: ...H AND NEUTRAL NOT CONNECTED BLACK TRANSFORMER YELLOW GREEN CAPACITOR MAIN WINDING MAIN WINDING 4 3 4 CURRENT CHARGER WINDING EXCITATION BATTERY 3 2 1 RED 10 10 BLUE BROWN ALT YELLOW GREEN ALT REGULATOR WCH J1 J2 11 11 DCC ct 1 DCC AC 1 BROWN 33 BLUE 33 BLUE 33 BROWN 33 DCC AC 1 YELLOW GREEN BLUE YELLOW GREEN BROWN BLACK DCC ct 1 RED 11 11 TRANSFORMER CURRENT EARTH AND NEUTRAL CONNECTED ...

Page 16: ...f all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load i e 30 of 3 kW is approx 1000W and let it run for approx 5 minutes 2 Press the STOP button 3 Switch to another 230V power source if available If a Masterswitch is installed this is done automatically 3 2 ...

Page 17: ...ted power for short periods 2 3 hours only The high peak current is meant for the ability to start electrical devices that need a high current for starting especially electric motors and compressors from a still stand state In order to prolong the generating set s life expectance the nominal electrical demand on the system should be about 80 or the rated generating set s maximum load Please note t...

Page 18: ...and polluting the environment The first service on the engine should be carried out after 50 hours of its life This also applies after a major over haul In the first 25 hours the engine should receive special attention Long periods of light or no load running in the first 25 hours may lead to cylinder glazing and high oil consumption For the same reason it is of the greatest importance to use the ...

Page 19: ... one should sump the oil Use tissues to avoid spilling oil in the capsule 4 3 REGULAR MAINTENANCE CHECK DAILY Oil level see fig 13 Take care the oil level is never below the mark Coolant level Hoses for loose connections or deterioration 1 Filling cap 2 Minimum oil level 3 Maximum oil level Figure 13 AFTER FIRST 50 HOURS Change oil Have the engine run until it is on temperature and stop it Drain o...

Page 20: ...y Check the level of the cooling liquid daily Change oil check and replace oil filter check and readjust valve clearance after first 50 hours Change oil 150 hours Check impeller water pump 300 hours Retighten cylinderhead bolts and readjust valve clearance 300 hours Replace fuel filter 300 hours Replace impeller water pump 500 hours Clean radiator with compressed air 1000 hours Retighten cylinderh...

Page 21: ...sidual magnetism Check the residual magnetism and flash the alternator refer to special procedures Capacitor loose or broken Check by independent excitation if the problem is in the capacitor or in the windings Rotor diodes broken Check the diodes in the rotor refer to special procedures The W SC3 has two diodes in the rotor It happens very rarely that both are broken When only one diode is broken...

Page 22: ...le connections When the engine is cranking well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes A failure code is displayed when a hardware failure at the generator is detected failure code problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging vol...

Page 23: ...leed air from fuel system refer to maintenance section Blocked injector Have the injector tested and cleaned if necessary Wrong valve clearance Adjust valve clearance Temporarily hunting this will disappear when engine has run in Engine speed drops Too much oil Drain oil to proper level Lack of fuel Check fuel supply system fuel pump and filter Lack of intake air Check air intake Choked exhaust sy...

Page 24: ... overloaded Digital Diesel Control will indicate overload Check electrical load and switch off some consumers Insufficient intake air Choked air filter Check intake air paths and filter clean and replace if necessary Fuel injector faulty Replace injector Valve clearance incorrect Readjust valve clearance Poor fuel quality Use better quality diesel Poor quality lubricating oil Use better quality oi...

Page 25: ... can be checked with a multimeter When both diodes are faulty the alternator will not generate any voltage When only one diode is faulty the alternator will generate about half the normal voltage The flexible lead connected to the diode should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reve...

Page 26: ...he generating set has to be taken out of its enclosure we strongly advise not to do this in a narrow space on a vehicle but to take out the complete set and take it to a workshop 2 To take out the generator all connections have to be taken off The outgoing hose on the oil cooler is most difficult to get to but can be reached from above by taking off the cover which is on the cylinder head of the e...

Page 27: ... to fig 17 40209011 Impeller gasket 3 4 5 50209021 Cover water pump 2 50209018 Bolts cover 1 40201251 Pump repair kit A consisting of Shaft 13 Bearings 2 pcs 10 O ring 9 Seals 2 pcs 8 Clips 1 set 11 12 40209010 Pump repair kit B same as repair kit A excluding the shaft Capacitor 40 micro farad 50209132 Measuring coil 50201290 Rotary diodes 2 pcs including varistors and capacitors 50201085 Alternat...

Page 28: ...p 1x 50209021 3 screw impeller 1x refer to impeller 4 Impeller 1x including screw 3 50209013 5 Gasket 1x 50209012 6 Pump housing 1x 50201013 7 Hose connector 2x 12 5 MM x 3 8 50221001 8 Seal 2x 50209015 9 O ring 1x 50209017 10 Bearing 2x 50209014 11 Clip 2x 50209019 12 Clip 1x 50209016 13 Impeller kit impeller gasket screw 40209011 Fig 18 Water pump type K ...

Page 29: ...NOTES EN W SC3 Mobile January 2011 29 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Page 30: ...NOTES 30 January 2011 W SC3 Mobile EN NOTES ...

Page 31: ...NOTES EN W SC3 Mobile January 2011 31 NOTES ...

Page 32: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl ...

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