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INFORMATION

December 2010 / M-SC6/8/10 / EN

2.5.14 Wiring codes and colours

number

colour

cable code no
cross section

battery > starter motor

red

25 mm2

starter motor > DDC

red

6 mm2

starter motor > LCP

red

2,5 mm2

battery > ground

black

25 mm2

ground > LCP ground (GND)

black

2,5 mm2

DDC > glow plug

brown

4 mm2

DDC > starter solenoid

yellow

2,5 mm2

LCP > fuel lift pump +

brown

1,5 mm2

LCP > fuel lift pump –

black

1,5 mm2

DDC > LCD

grey

1,5 mm2

DDC > oil pressure switch

purple

1 mm2

LCP > oil pressure switch

purple/black

1 mm2

DDC > oil temperature switch

blue

1 mm2

LCP > oil temperature switch

blue/black

1 mm2

DDC > exhaust temperature switch

blue/green

1 mm2

LCP > exhaust temperature switch

blue/rose

1 mm2

DDC > fuel solenoid (hold)

green

1,5 mm2

DDC > fuel solenoid (pull)

pink

1,5 mm2

DDC > fuel solenoid (com.)

black

1,5 mm2

B+ terminal alternator > starter motor

red

6 mm2

DDC >R terminal alternator

white

1,5 mm2

DDC > L terminal alternator

orange

1,5 mm2

DDC > current measuring transformer

black

1 mm2

DDC > current measuring transformer

red

1 mm2

DDC > LCP

black

1,5 mm2

DDC > LCP

red

1,5 mm2

DDC > LCP

red/green

1,5 mm2

DDC > generator AC output

brown

1 mm2

DDC > generator AC output

blue

1 mm2

DDC=Digital Diesel Control Unit
LCP=Local Control Panel

Содержание M-SC6

Страница 1: ...10 3000 RPM Marine diesel generating set 230V 50Hz Digital Diesel Control V1 December 2010 Art nr 40200351 WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu ...

Страница 2: ... 4 Components 10 2 4 1 Main components to identify 10 2 4 2 Generator control panel 13 2 4 3 Remote control panel 13 2 5 Technical Information 13 2 5 1 AC alternator 13 2 5 2 Engine 13 2 5 3 Digital Diesel Control system 13 2 5 4 Battery charger 14 2 5 5 Alarms and shut down 14 2 5 6 Control 14 2 5 7 Remote control 14 2 5 8 Hour counter 14 2 5 9 Load indicator 14 2 5 10 Fuel specification 14 2 5 1...

Страница 3: ...al faults 27 5 1 1 General 27 5 1 2 Trouble shooting table 27 5 2 Engine faults 29 5 2 1 General 29 5 2 2 Trouble shooting table 29 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 5 3 2 Testing rotary rectifier diodes 33 5 3 3 Winding resistant values 34 5 3 4 Meggering 34 5 4 Special procedures engine 34 5 4 1 Se...

Страница 4: ...nces shall be held liable for any inaccuracy or the consequences thereof WARNING A warning symbol draws attention to special warnings instructions or procedures which if not strictly observed may result in damage or destruction of equipment severe personal injury or loss of life DANGER This danger symbol refers to electric danger and draws attention to special warnings instructions or procedures w...

Страница 5: ...reinstallation There is no cover for labour needed to get access to the generator for example to remove equipment or bulkheads etc Goods to be delivered under warrantee will be invoiced Only after the faulty goods are returned will the invoice be credited Payment in advance may be required or guaranteed by credit card If after the faulty goods are returned it is indicated that the failure was not ...

Страница 6: ...Power is rated at an ambient temperature of 40 C and a seawater temperature of 25ºC For higher temperatures the generating set has to be derated 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 3000 rpm 60 Hz correlates with 3600 rpm 5 ...

Страница 7: ...inst earth insulation failures In the standard delivery neutral and ground are not connected To make a connection between neutral and ground could be necessary as part of a specific insulation failure protection system Small pleasure craft in Europe is submitted to The Recreational Craft Directive 94 25 EC The guidelines of this directive refer to ISO 13297 When the installation complies with this...

Страница 8: ...and explosion Avoid refilling the fuel tank while the engine is running When oil or fuel is leaking do not use the generating set Do not run the engine close to explosives 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 Poor electrical...

Страница 9: ... frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s left side The set is not self contained and is only operable after proper installation using additional accessories and installation materials Installation accessories are listed in the installation manual and are available through the supplier of the genera ting se...

Страница 10: ...2 Fuel injector M SC6 2x M SC10 3x 03 Glow plug M SC6 2x M SC10 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 Raw water pump 20 Fuel lift pump 2...

Страница 11: ...ine mounting 31 Fuel in Ø8mm 32 Battery negative 33 Battery positive 34 Fuel out Ø8mm 35 Raw water inlet 36 V belt 37 Engine coolant pump 38 Exhaust manifold watercooled 40 Temperature switch 41 Thermostat housing 42 Filler cap engine oil 43 Filler cap engine coolant 44 Rocker cover 45 Hoist eye rear 46 Expansion tank 47 Bypass cooling water out 48 Bypass cooling water in 49 Generator 50 Exhaust h...

Страница 12: ...ounting 31 Fuel in Ø8mm 32 Battery negative 33 Battery positive 34 Fuel out Ø8mm 35 Raw water inlet 36 V belt 37 Engine coolant pump 38 Exhaust manifold water cooled 40 Temperature switch 41 Thermostat housing 42 Filler cap engine oil 43 Filler cap engine coolant 44 Rocker cover 45 Hoist eye rear 46 Expansion tank 47 Bypass cooling water out 48 Bypass cooling water in 49 Generator 50 Exhaust hose ...

Страница 13: ...switching to relieve the burden on the engine The M SC8 and 10 can be equipped with an optional voltage regulator to keep the voltage tolerance within 2 Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The M SC6 and 8 generating set is based on the Mitsubishi L2E 2 cylinder diesel engine The M SC10 on the L3E 3 cylinder The en...

Страница 14: ... fuel oil which conforms to the standards for use in modern diesel engines Fuel free from water and contaminants is of the utmost importance 2 5 11 Oil information 1 Specification The oil must be suitable for oil changes as specified in the maintenance chapter The engine must be run on heavy duty lubricating oil meeting the requirements of API class CD CF or CF_4 It is very important to use the co...

Страница 15: ... 952 cm3 Bore X stroke 76x70 mm 76x70 mm 76x70 mm Combustion air consumption 0 9 m3 min 0 9 m3 min 1 4 m3 min Continuous power engine 5 kW 6 4 kW 10 5 kW Cooling system indirect cooling by raw water 10 15 l min Cooling water pump PTO driven WhisperPower self priming impeller pump type M Fuel lift pump engine electric pump 12 V DC additional pump available upon request Starting battery optional 60 ...

Страница 16: ...emperature 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 rose 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 terminal ...

Страница 17: ...INFORMATION EN M SC6 8 10 December 2010 17 2 5 15 Lay out control wiring Fig 11 Lay out control wiring ...

Страница 18: ...trical 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 ...

Страница 19: ...wer So the 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 an...

Страница 20: ...t button to initiate the full automatic starting procedure You can monitor the procedure on the display In operation checks 1 Check for abnormal noise or vibration 2 Check the voltage 3 Check sea water flow at exhaust outlet 4 Power source selector switch off shore power generator power Switch to power source generator If a Masterswitch is installed this operates automatically 5 Before loading the...

Страница 21: ... necessary to prime the fuel system Refer to bleeding fuel system instructions in the maintenance chapter A restart protection prevents starting the engine when it is already running which could cause damage In the event of starting problems numerous attempts are made close the sea water inlet cock while cranking to prevent the outlet system and engine to fill up with water During the starting pro...

Страница 22: ...emove the battery while the engine is running or any electrical cable while the battery is connected in the circuit Only disconnect the battery with the engine stopped and all switches in OFF position Stopping the generating set 1 Avoid stopping of the generator abruptly after a long period of operation at high load Doing so you avoid unnecessary thermal load to your generating set Act as follows ...

Страница 23: ...lazing 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 to prime the ...

Страница 24: ...fresh oil Start the engine again and have it run for 5 minutes Stop the engine again and pause for a few minutes to let the oil gather in the crankcase Check the level again and add oil when necessary Check and tighten nuts bolts and unions paying particular attention to the fuel system Observe the exhaust at the normal full load The exhaust must be free from soot Do not allow the engine to run wi...

Страница 25: ...ck the cooling system The engine cooling liquid is indirectly cooled by raw water via a heat exchanger The alternator is cooled by seawater which is pumped by the PTO driven impeller pump through the cooler elements in the generator housing All parts of the cooling system are of corrosion free and seawater resistant materials such as brass and gunmetal In case of gathering of dirt in the system it...

Страница 26: ...the engine and take loose the inlet of the raw water pump Drain the water from the water lock Crank the engine having the raw water inlet sucking anti freeze from a can until the pump heat exchanger and manifold are filled 5 The coolant can stay in the engine 6 Disconnect the battery and store it in a place free of frost and dry and charge it regularly 7 Close inlet and outlet openings with tape 8...

Страница 27: ...M SC8 and 10 A RPM drop of 1 at full load is acceptable Therefore a no load setting should be at 3030 RPM 50 5 Hz Under no circumstances should the RPM under full load be below 2970 RPM 49 5 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 er...

Страница 28: ...ve capacitors Check capacitor specification and replace capacitors if necessary Presence of a strong capacitive load leading power factor Compensate for this capacity and seek for experts advice WHISPERPOWER customers service Defective voltage regulator Optional for M SC8 10 Replace voltage regulator Generator voltage fluctuates Disturbances on the electrical system user side Check if electrical l...

Страница 29: ...PRESSURE Oil pressure failure AC VOLTAGE Generator AC output voltage is either too high or too low HIGH CURRENT Generator is in overload FREQUENCY Output frequency of the generator is too low 5 2 2 Trouble shooting table PROBLEM CAUSE SOLUTION Diesel engine fails to crank the starter makes clicking noises or the engine cranks very slowly Almost certainly this is an electrical problem Display will ...

Страница 30: ...ump clean or replace if necessary Faulty fuel lift pump Check and repair Choked air filter Lack of air Check the air intake Choked exhaust system exhaust blocked rubber exhaust hose kinked Check the exhaust hose Air in the fuel pipes Bleed air from fuel system refer to maintenance section Faulty electronic governor only if applied Replace faulty parts Blocked injector Have the injector tested and ...

Страница 31: ...r blocked Air or water in the fuel Blocked air or fuel filter Check cooling water system flow water pump inlet water filter coolant flow Loss of compression by wear out or damage Repair by WhisperPower service V belt broken or loose Readjust or replace V belt Thermostat faulty Check thermostat and replace Sooty black exhaust Generator is being overloaded Digital Diesel Control will indicate HIGH C...

Страница 32: ...en impeller Water strainer choked Heat exchanger choked Check the cooling system thoroughly Broken or slipping V belt Replace and adjust the V belt tension Faulty thermostat Check the thermostat or replace 5 2 3 Warnings Generator must be shut off immediately if Motor RPM suddenly rises or drops Unusual noise comes from generating set Exhaust gases suddenly colour dark Engine failure warning light...

Страница 33: ...es When flashing does not bring back voltage the capacitor s should be renewed When this does not help the rotating rectifier diodes should be tested and a winding resistant test should be executed 5 3 2 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter When the diode is faulty the alternator will not generate any voltage The flexible lead connected to the di...

Страница 34: ...ult is suspected one can do a high voltage resistance test MEGGERING This procedure should be carried out by an expert 5 4 SPECIAL PROCEDURES ENGINE 5 4 1 Setting the RPM RPM is set by the manufacturer and should not need readjustment However a very slight offset after running in could occur RPM can be measured by a frequency meter M SC8 and 10 When adjustments are necessary this can only be done ...

Страница 35: ... the No 1 cylinder Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation If the rocker arms move piston no 1 is on the T D C of the intake or exhaust stroke In such case turn the crankshaft 360 in the direction of engine rotation again No 1 piston is now at T D C of the compression stroke 4 To adjust the valve clea...

Страница 36: ...er mountings should break down The nuts of the fail safes are diagonal to each other When the 6 nuts in total are removed the generating set can be lifted out the canopy 5 nuts are well accessible The sixth nut has to be removed by taking out the bold from the bottom of the canopy 2 The easiest way to get the generator out of its capsule is by lifting the set using the lifting eye and removing the...

Страница 37: ...TROUBLE SHOOTING EN M SC6 8 10 December 2010 37 Figure 26 exploded view sound shield M SC6 8 and 10 ...

Страница 38: ...repair kit B same as repair kit A excluding the shaft 50201811 and O ring 50201814 50201820 Heat exchanger complete with appendages M SC6 and 8 50201822 Water hoses with clamps M SC6 and 8 50201720 Heat exchanger complete with appendages M SC10 50201722 Water hoses with clamps M SC10 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50101886 A...

Страница 39: ...SPARE PARTS LIST EN M SC6 8 10 December 2010 39 Fig 27 Water pump type M ...

Страница 40: ...MAINTENANCE LOG 40 December 2010 M SC6 8 10 EN MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Страница 41: ...NOTES EN M SC6 8 10 December 2010 41 NOTES ...

Страница 42: ...NOTES 42 December 2010 M SC6 8 10 EN NOTES ...

Страница 43: ...NOTES EN M SC6 8 10 December 2010 43 NOTES ...

Страница 44: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl ...

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