Whisper Power W-SQ25 User Manual Download

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USERS MANUAL FOR MOBILE APPLICATIONS

W-SQ25

- 1500 RPM -

Mobile diesel generating set 230/400V / 50Hz

Digital Diesel Control

WHISPER POWER BV

Kelvinlaan 82

9207 JB Drachten

Nederland

Tel.: +31-512-571550

Fax.: +31-512-571599

www.whisperpower.eu

V1 January 2009

rt.

Summary of Contents for W-SQ25

Page 1: ...TIONS W SQ25 1500 RPM Mobile diesel generating set 230 400V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 January 2009 Art nr 40200621 ...

Page 2: ...n 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 13 2 5 3 Digital Diesel Control system 13 2 5 4 Battery charger 13 2 5 5 Alarms and shut down 13 2 5 6 Monitoring 13 2 5 7 Control 13 2 5 8 Remote control 14 2 5 9 Hour counter 14 2 5 10 Load indicator 14 2 5 11 Fuel specification 14 2 5 12 Oil...

Page 3: ...e 26 4 3 2 Putting out of service 26 5 TROUBLE SHOOTING 27 5 1 Alternator electrical faults 27 5 1 1 General 27 5 1 2 Trouble shooting table alternator 27 5 2 Engine faults 28 5 2 1 General 28 5 2 2 Trouble shooting table engine 29 5 2 3 Warnings 31 5 2 4 Service address 32 5 3 Special procedures alternator 33 5 3 1 Automatic Voltage Regulator AVR 33 5 3 2 Residual voltage check excitation procedu...

Page 4: ...ER This danger symbol refers to electric danger and draws attention to special warnings instructions 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 400V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users...

Page 5: ...lure was not covered by guarantee 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 ...

Page 6: ...t the nominal frequency The W SQ25 can be connected for different voltages in single phase or tri phase The nameplate indicates the connection as made in the factory BE AWARE THAT THE CONNECTIONS COULD BE RECONNECTED BY FORMER USERS 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 1500 rpm 5 CURRENT This shows the maximum current that is acceptable ...

Page 7: ...lectrical system to be carried out by qualified electricians Connection and protection must be done in accordance with local standards Using the auto 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 2 1 3 Earth insulation failures Acco...

Page 8: ...sives or gasses Hydrogen gas generated by charging batteries is explosive Ensure for proper ventilation Do not smoke 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 PORTABLEFIREEXTINGUISHERT...

Page 9: ...5 2 3 1 Features This generating set includes a 4 cylinder diesel engine which is connected by close coupling to a tri phase synchronous 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 The complete set is again on rubber mountings All cables and hoses are guided through the capsule s sides Th...

Page 10: ...25 Fig 5 Top View main components W SQ25 15 Filler cap engine oil 16 Filler cap engine coolant 17 Rubber engine mounting 18 Rocker cover 01 Thermostat housing 02 Boiler connection 03 Engine coolant pump 04 V belt 05 Exhaust connection 06 Engine coolant OUT 07 Battery 08 Battery 09 Fuel out 10 Fuel in 11 Engine coolant IN 12 Rubber engine mounting ...

Page 11: ...Engine oil dipstick 31 Fuel solenoid 32 Oil filter 33 Injection pump air bleeding screw 34 Fuel lift pump for manual priming 35 Fuel injection pump 37 Temperature switch 38 Hoist eye front 39 Alternator 40 Exhaust manifold watercooled 41 Hoist eye alternator 42 Digital Diesel Control DDC 43 Expansion tank 44 Power take off hydro pump 45 Remote control 46 AC power output 48 Coolant injection bend 4...

Page 12: ...e regulator controls and keeps constant the average voltage of one phase The voltage setting on the AVR can be adjusted with the help of a trimmer V between 185 and 290 Volts See par 5 3 1 A frequency control progressively deactivates the machine when the drive motor speed drops below a pre set adjustable threshold preventing over excitement at low operating speeds and abating the load engage effe...

Page 13: ...our identification data to determine which system is applied The system is designed according to the energise to run system The Digital Diesel Control is a very advanced microprocessor based full automatic system Besides automatic start the system offers many monitoring options Refer to the separate Digital Diesel Control users manual The microprocessor unit is located in the black box on top of t...

Page 14: ...e 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 the oil filter the content of the crankcase is 9 l Including the oil filter it is 9 3 l Do not overfill with lubricating oil as this may have a detrimental effect on engine performance 4 Oil pressure Minimum at...

Page 15: ...ng current AC tri phase re connectable to take off single phase or dual voltage Output rating Whisper 25kVA at powerfactor cos phi 1 Voltage tolerance 2 balanced load Frequency tolerance 3 Alternator Air cooled brushless four pole twelve wire synchronous Voltage regulation AVR MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on rubber anti vibration mounts Generator s...

Page 16: ...anuary 2009 W SQ25 for mobile applications EN 2 5 15 Electrical diagram control wiring W SQ25 Fig 13 Electrical Diagram control wiring W SQ25 for mobile applications Optional control for two speeds fans See chapter 4 8 ...

Page 17: ...INFORMATION EN W SQ25 for mobile applications January 2009 17 2 5 16 Terminal modes 115VAC 230VAC 400VAC 50Hz Fig 14 Terminal modes W SQ25 ...

Page 18: ...09 W SQ25 for mobile applications EN 2 5 17 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR REFERTO2 1 3 USERMANUALWHISPER25U TOCONNECTNEUTRALTOGROUND Fig 15 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR ...

Page 19: ...obile applications January 2009 19 2 5 18 AC Wiring Diagram single phase with AVR 230V Hz Double Delta TOCONNECTNEUTRALTOGROUND REFERTO2 1 3 USERMANUALWHISPER25U Fig 16 AC Wiring Diagram single phase with AVR 230V Hz Double Delta ...

Page 20: ...radiator fan control DIMENTION BOX 270x270x180 MM JUNCTION BOX AIR FANS 12VDC K1 K2 230 115VAC 200VA TRAFO 230VAC Fig 18 Electrical diagram fan control using a 230V AC radiator fan with two speeds fans optional Fig 17 Electrical diagram for standard fan control using a 230V AC radiator fan ...

Page 21: ...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 22: ...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 SQ25 is designed so as not to overheat even under extreme conditions Do not run the generator for very...

Page 23: ...r overhaul In the first 50 hours the engine should receive special attention Long periods of light or no load running in the first 50 hours may lead to 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 ...

Page 24: ...ilter 02 01 01 Engine oil filter 02 Engine oil dipstick Fig 22 Location engine oil filter and dipstick A smeer of oil has to be put on the seal of the filter before fitting the filter The filter should be fastened manually when the rubber touches the metal turn 3 4 further 4 2 6 Tensioning V belt The alternator bracket allows for readjust of the V belt Deflections should be 13 mm see fig 24 Fig 24...

Page 25: ...0 HOURS Change oil Check the battery acid level not applicable when Whisper Power batteries are used Check battery terminals for corrosion Check and readjust V belt AFTER FIRST 300 HOURS Retighten the cylinder head bolts and adjust the valve clearance Refer to 5 4 2 EVERY 300 HOURS Check the impeller of the engine coolant pump Replace the oil filter Replace the fuel filter Replacement depends or t...

Page 26: ...olts and readjust valve clearance 1000 hours Check and clean radiators 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air cleaner element 2000 hours 4 3 2 Putting out of service When not using the generating set for a longer period it is recommended to execute an engine preservation procedure 1 Clean the engine 2 Loosen th...

Page 27: ...der no circumstances should the RPM under full load be below 1470 RPM 49 Hz When 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 cha...

Page 28: ...lance remove the sense wires to the phase with the highest load and check if the voltage on the other phases is not too low Generator voltage fluctuates Disturbances on the electrical system user side Check if electrical load is fluctuating AVR reacts on fluctuating load Readjust the stability setting on the AVR trimmer ST Engine runs irregularly When engine runs irregularly see section Engine run...

Page 29: ...wer viscosity Wiring control system faulty During the normal starting process the battery voltage drops to 11V with a fully charged battery If the voltage does not drop during starting the electrical connection is faulty If the battery voltage drops lower than 11V then the battery has been discharged too deep Starter motor faulty Repair the starter motor Starter is turning engine smoothly but engi...

Page 30: ...maged engine Repair by Whisper Power service Engine does not stop on command Fuel solenoid is not switching off Loss of control Faulty Digital Diesel Control unit Stop the engine manually by the stop handle Check wire connections to stop solenoid Check solenoid valve function Replace if necessary Engine exhaust smokes Faint blue smoke generally the result of light load Increase load Heavy blue smo...

Page 31: ...crease load up to 70 of nominal power and have the engine run for a few hours Loss of power Wrong measurement Check if the load is measured correctly Does the Amp meter show the correct value When calculating the load by multiplying voltage and amps this should be done by using the exact values taking into account the power factor of the consumers When any doubt measure the power directly with an ...

Page 32: ...for mobile applications EN 5 2 4 Service address If you cannot correct a problem with the aid of the mal function table contact your Whisper Power Service Centre or Whisper Power Netherlands for an extended service list tel INT 31 512 571550 ...

Page 33: ... adjusting potentiometer V Take the generating set to its nominal speed and turn until the required voltage is obtained If a small variation in speed causes a change in voltage then the bottom speed protection should first be calibrated The voltage reference orange wires should be connected to terminals 0 and 115 for an output voltage between 100 and 140V factory setting to terminals 0 and 230 for...

Page 34: ...eading in both directions In case of faulty diodes replace the rectifier unit One can get access to the diode unit by taking off the backend of the alternator Fig 29 Location rectifier diode block 5 3 4 Winding resistant values If after establishing and correcting any fault on the AVR and diodes and output is still low when separately excited then the main rotor stator auxiliary and exciter stator...

Page 35: ...ine When both procedures are executed be sure to retighten the cylinder head bolts before adjusting the valve clearance When retightening the cylinder head bolts drain the coolant by removing the coolant drain plug ref to fig 4 Loosen the bolts slightly remove the rocker assembly the rocker arms shaft and stays and then retighten the bolts to the specified torque in the numerical order illustrated...

Page 36: ...cylinder 3 Adjusts the valves of cylinder 3 and turn the crankshaft further clockwise to the T D C of cylinder 4 and finally to 2 5 4 3 Disassembling instructions It could be necessary for repair or checks to disassemble the generating set Following instructions will help 1 The design of the W SQ25 makes it possible to do most repairs on the spot The connections of the alternator are very accessib...

Page 37: ...ng or to replace a mounting can be done according to the drawing below figure 34 Fig 34 Exploded view rubber mountings 5 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 6 Reassembling the generating set one should take care of alignment cleaning the surfaces between engine and alternator and tighten the bolts...

Page 38: ...50230007 Air cleaner element 50209145 Measuring coil Wh 25 3 pcs 50208010 Rotary diode three phase 50208015 Alternator bearing including O ring 50208020 Voltage regulator 50209104 Local control panel 50209099 Digital Diesel Control Unit 3 phase 50212170 Fuses 10 Amps 50212154 Fuses 3 Amps 50212197 Fuses 32 x 6 3 2 Amps 50201559 Wiring loom complete 50209102 Digital Diesel Remote control panel 1300...

Page 39: ...MAINTENANCE LOG EN W SQ25 for mobile applications January 2009 39 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Page 40: ...NOTES 40 January 2009 W SQ25 for mobile applications EN NOTES ...

Page 41: ...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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