Whisper Power W-SQ 6 User Manual Download

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USERS MANUAL FOR MOBILE APPLICATIONS

W-SQ6

- 1500 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 October 2008

rt.

Summary of Contents for W-SQ 6

Page 1: ...IONS W SQ6 1500 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 October 2008 Art nr 40200131 ...

Page 2: ... 3 3 Documentation 9 2 4 Components 10 2 4 1 Main components to identify 10 2 4 2 Generator control panel 12 2 4 3 Remote control panel 12 2 5 Technical Information 12 2 5 1 AC alternator 12 2 5 2 Engine 12 2 5 3 Digital Diesel Control system 12 2 5 4 Battery charger 12 2 5 5 Alarms and shut down 12 2 5 6 Control 13 2 5 7 Remote control 13 2 5 8 Hour counter 13 2 5 9 Load indicator 13 2 5 10 Fuel ...

Page 3: ...enance 26 4 3 1 Maintenance schedule 27 4 3 2 Putting out of service 27 5 TROUBLE SHOOTING 28 5 1 Alternator electrical faults 28 5 1 1 General 28 5 1 2 Trouble shooting table alternator 28 5 2 Engine faults 29 5 2 1 General 29 5 2 2 Trouble shooting table engine 30 5 2 3 Warnings 32 5 2 4 Service address 32 5 3 Special procedures alternator 33 5 3 1 Residual voltage check excitation procedure 33 ...

Page 4: ...tructions or procedures which if not strictly observed may result in electrical shock which will result in severe personal injury or loss of life DANGER Realise that people are not used to have 230V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance personal of garages that do service on the vehicle 1 2 SERVICE ...

Page 5: ...ee a credit will not be issued For example if a Printed Circuit Board is returned with clear damage caused by water guarantee will be refused Freight costs to deliver spares by normal mail or carriers is covered under guarantee Special services like express mail overnight delivery etc are not covered Taxes and duties are not covered For shipments to remote areas any additional costs incurred over ...

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

Page 7: ...o start stop interval mode the generator can start unexpectedly When working on the electrical system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery Warning signs indicate parts which could be live 2 1 3 Earth insulation failures According to local regulations and depending on the application it could be necessary to take measures ...

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

Page 9: ... 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 10: ...Fuel injector 3x 03 Glow plug 3x 04 Alternator 12VDC 05 Engine oil dipstick 06 Coolant drain plug 07 Oil sump hand pump 10 Air cleaner element 11 Control panel 12 Fuses 13 Digital Diesel Control DDC 14 Identification plate 15 Hoist eye front 16 Injection pump air bleeding screw 17 Engine speed adjustment screw 18 Fuel solenoid 19 Water pump of the alternator cooling circuit 20 Fuel lift pump 21 En...

Page 11: ...r 50 Hoist eye rear 51 Expansion tank 52 AC Generator 53 Exhaust 1 54 AC power output 55 Remote control 25 Dry exhaust 26 Temperature switch alternator 27 Starter motor solenoid 28 Starter motor 29 Rubber engine mounting 30 Coolant generator out 31 Coolant engine in 32 Coolant engine out 33 Battery negative 34 Fuel in Ø8mm 35 Fuel out Ø8mm 36 Battery positive 37 Coolant generator in 38 V belt 39 E...

Page 12: ...load switching to relieve the burden on the engine The alternator is water cooled and the cooling liquid is cooled by a radiator Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The W SQ6 generating set is based on the Mitsubishi L3E 3 cylinder diesel engine The engine is indirectly injected The engine is water cooled and the ...

Page 13: ...nts of API class CD CF or CF_4 It is very important to use the correct oil specification Very often local oil suppliers recommend a higher class because they assume that a higher class is allowed This is not the case One should not follow these recommendations Using the wrong specification will cause high oil consumption 2 Oil viscosity We recommend a multigrade oil 15W40 3 Oil capacity Excluding ...

Page 14: ...c start stop ELECTRICAL SPECIFICATIONS Output voltage 230V 50 Hz alternating current AC single phase Output rating 5kVA 5kW at powerfactor cos phi 1 Voltage tolerance 5 Frequency tolerance 1 electronic governor Alternator brushless four pole synchronous Voltage regulation Capacitor AVR optional MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on rubber anti vibration ...

Page 15: ...DC oil temperature switch 7 blue 1 mm2 LCP oil temperature switch 7 blue black 1 mm2 DDC exhaust temperature switch 8 blue green 1 mm2 LCP exhaust temperature switch 8 blue pink 1 mm2 DDC fuel solenoid hold 9 green 1 5 mm2 DDC fuel solenoid pull 20 pink 1 5 mm2 DDC fuel solenoid com 17 black 1 5 mm2 B terminal alternator starter motor 21 red 6 mm2 DDC R terminal alternator 18 white 1 5 mm2 DDC L t...

Page 16: ... 16 October 2008 W SQ6 for mobile applications EN 2 5 15 Lay outs control wiring Fig 10 Electrical Diagram control wiring W SQ6 using a 230V AC radiator fan Optional control for two speeds fans See chapter 2 5 17 ...

Page 17: ...INFORMATION EN W SQ6 for mobile applications October 2008 17 Fig 11 Electrical Diagram control wiring W SQ6 using a 24V DC radiator fan ...

Page 18: ...INFORMATION 18 October 2008 W SQ6 for mobile applications EN Fig 12 Electrical Diagram control wiring W SQ6 using a 12V DC radiator fan ...

Page 19: ...g 13 Electrical diagram 230V EARTH AND NEUTRAL CONNECTED EARTH AND NEUTRAL NOT CONNECTED L1 PE N DDC AC 1 230V 50Hz ROTOR EXCITATION WINDING MAIN WINDING MAIN WINDING STATOR CAPACITOR DDC ct 1 YELLOW GREEN BLACK 4 RED 3 BLACK 4 RED 3 GREEN 1 GREEN 2 RED 11 BLACK 11 BROWN YELLOW GREEN BLUE BLUE 33 BROWN 33 ...

Page 20: ...DC K1 K2 230 115VAC 200VA TRAFO 230VAC Fig 15 Electrical diagram fan control using 230V AC radiator fans with two speeds fans optional FUSE 5A FUSE 6 3A FUSE 6 3A FUSE 5A FUSE 5A 15 16 5 6 7 8 13 14 11 1 4 2 3 K2 K1 K2 K1 BAT 12V PUMP 12V GENERATOR 230VAC L1 K1 BAT 12V GENERATOR 230VAC N 230VAC 230VAC 45 35 C 80 70 C THERMOSTAT COOLER ENGINE GENERATOR RADIATOR COOLER ENGINE RADIATOR COOLER GENERAT...

Page 21: ...U4 CU0 75 45 35 C CU0 75 4 1 2 3 5 6 7 CU2 5 CU2 5 8 9 10 JUCTION BOX AIR FANS FUSE 20 40A K3 2 1 4 3 5 7 6 8 K1 10 9 K2 DIMENIONS BOX 160x160x90 MM Fig 16 Electrical diagram fan control using 12V or 24V DC radiator fans optional FUSE 20 40A BAT THERMOSTAT COOLER ENGINE GENERATOR CONTROL PANEL PUMP 2 1 1 9 4 3 2 6 7 5 8 10 K1 K2 K3 K1 K2 K3 45 35 C 80 70 C M M 2 1 2 3 4 5 5 3 1 2 5 3 RADIATOR COOL...

Page 22: ... electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the fuel pump without levers and other me...

Page 23: ...d to 70 of maximum load Stopping generator 1 Switch off all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load and let it run for approx 5 minutes 2 Press the STOP button 3 Switch to an other AC power source if available If a Mass Systemswitch is installed this...

Page 24: ...starting especially electric motors and compressors from a still stand state In order to prolong the generating set s life expectancy the nominal electrical demand on the system should be about 70 or the rated generating set s maximum load Please note this when switching on your electrical devices Nevertheless the W SQ6 is designed so as not to overheat even under extreme conditions Do not run the...

Page 25: ...o cylinder glazing and high oil consumption For the same reason it is of the greatest importance to use the right oil specification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel lines Ensure there is sufficient fuel The system is self bleeding The first time starting up or after running out of fuel it could be necessary t...

Page 26: ...l level Fig 24 CHECK DAILY Level cooling liquid Hoses for loose connections or deterioration AFTER FIRST 50 HOURS Change oil and replace the oil filter Have the engine run until it is on temperature and stop it Replace the oil filter Drain oil by the sump pump into a suitable retainer and fill up with fresh oil Start the engine again and have it run for 5 minutes Stop the engine again and pause fo...

Page 27: ...ss than 100 hours a year the oil should be changed yearly 4 3 1 Maintenance schedule Check oil level daily Check the level of the cooling liquid daily Change oil and oil filter after first 50 hours Check and tighten nuts bolts etc after first 50 hours Check exhaust after first 50 hours Check and readjust V belt after first 50 hours Check electrical connections after first 50 hours Change oil 150 h...

Page 28: ... the problem is in the RPM refer to the engine fault finding paragraph Digital Diesel Control system will help to indicate failures and display causes 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 voltage AC ALTERN TEMP AC alternator temperature is too high WATER TEMP Co...

Page 29: ... generator peak output current This could be remedied by providing stronger capacitors to the motor or using a soft start Inquire at your nearest Whisper Power dealer or directly at the manufacturer Whisper Power in the Netherlands 5 2 ENGINE FAULTS Remove 3 Amp fuse in the control panel while working on the generator to prevent the engine from starting 5 2 1 General Most electrical problems relat...

Page 30: ... Air in fuel lines Check fuel filter and fuel lift pump clean or replace if necessary Bleed air from fuel system refer to maintenance section Wrong valve clearance Adjust valve clearance Low compression because of dirty valves Clean valves Take off the injection bent and inspect the outlet port When little rust in the port clean the valve by taking off the valve spring and rotate until rust is rem...

Page 31: ...ine starts but stops after 10 up to 30 seconds Protection system stops the engine this can be caused by oil pressure failure lack of cooling water exhaust temperature alarm Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure Refer to paragraph 2 5 5 and 3 2 2 for information on the alarm system Bypassing the switches can help to confirm the failure Engin...

Page 32: ...icking or damaged piston ring Have the compression measured Clean or replace the rings Wear out of cylinder Have the compression measured and have the engine overhauled Over temperature Overload Take away the overload Low level of coolant or air in the cooling system Fill up with coolant and release air bubbles Check if there are air blocks in the system refer to the installation manual Broken imp...

Page 33: ... terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replace the diode 5 3 3 Winding resistant values ...

Page 34: ...ocker stay tightening torque M8 bolt 15 22 Nm The clearance of both intake and exhaust valves should be 0 25 mm in cold condition Set the piston of the first cylinder to be adjusted to top dead centre T D C of compression stroke The T D C of compression stroke can be found by aligning the T D C mark notch on the crankshaft pulley with the mark on the gear case ref to fig 29 First align the T D C m...

Page 35: ...rator out of its capsule is by lifting the set with the aid of the lifting eyes 4 One can take off the complete alternator housing Before the alternator can be taken off all cables and wiring has to be taken loose first 5 The rotor can be taken off by removing the bold which goes through the shaft normal clockwise threaded The end of the shaft is specially threaded to push off the rotor from the c...

Page 36: ...ngs 2 pcs 50209014 O ring 50209017 Seals 2 pcs 50209015 Clips 1 set 50209019 O ring 50201814 50209010 Pump repair kit B same as repair kit A excluding the shaft 50201811 and O ring 50201814 50201060 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50201887 Alternator bearing including O ring 50209140 Voltage regulator optional 50209104 Local ...

Page 37: ...SPARE PARTS LIST EN W SQ6 for mobile applications October 2008 37 Fig 31 Water pump type M ...

Page 38: ...MAINTENANCE LOG 38 October 2008 W SQ6 for mobile applications EN MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Page 39: ...NOTES EN W SQ6 for mobile applications October 2008 39 NOTES ...

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

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