User manual M-SQ 8, 10 ENG

USERS MANUAL

M-SQ8 / 10

- 1500 RPM -

Marine diesel generating set 230V / 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. July 2010

CONTENTS

CONTENTS:

1 INTRODUCTION .............................................................................................................................................................. 4

1.1

General .............................................................................................................................................................. 4

1.2

Service and maintenance ................................................................................................................................... 4

1.3

Guarantee .......................................................................................................................................................... 4

1.4

Liability ............................................................................................................................................................... 5

1.5

Identification ....................................................................................................................................................... 6

1.5.1

General .............................................................................................................................................. 6

1.5.2

Identification plate ............................................................................................................................. 6

2 INFORMATION ................................................................................................................................................................ 7

2.1

Safety ................................................................................................................................................................. 7

2.1.1

General .............................................................................................................................................. 7

2.1.2

Electrical safety ................................................................................................................................. 7

2.1.3

Earth insulation failures ..................................................................................................................... 7

2.1.4

Installation ......................................................................................................................................... 7

2.1.5

Operation ........................................................................................................................................... 8

2.1.6

Fire and explosion ............................................................................................................................. 8

2.1.7

Chemicals .......................................................................................................................................... 8

2.2

Transport, lifting and storage .............................................................................................................................. 9

2.3

The M-SQ8/10 .................................................................................................................................................... 9

2.3.1

Features ............................................................................................................................................ 9

2.3.2

Remote control .................................................................................................................................. 9

2.3.3

Documentation .................................................................................................................................. 9

2.3.4

Accessories included in the standard delivery ................................................................................... 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 ..................................................................................................................... 13

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 specification ............................................................................................................................. 13

2.5.11

Oil information ................................................................................................................................. 13

2.5.12

Cooling liquid ................................................................................................................................... 13

2.5.13

Technical data ................................................................................................................................. 14

2.5.14

Wiring codes and colours ................................................................................................................ 15

2.5.15

Lay out control wiring ....................................................................................................................... 16

2.5.16

Electrical diagram 230 V AC / 50 Hz ............................................................................................... 17

2.5.17

Diagram electronic governor M-SQ10 ............................................................................................. 18

2

January 2010 / M-SQ8 & 10 / EN

CONTENTS

3 OPERATION .................................................................................................................................................................. 19

3.1

General ............................................................................................................................................................ 19

3.2

Operating Instructions ...................................................................................................................................... 19

3.2.1

Summarised operating instructions (daily use) ................................................................................ 19

3.2.2

Extended operating instructions ...................................................................................................... 19

4 MAINTENANCE ............................................................................................................................................................. 22

4.1

Alternator .......................................................................................................................................................... 22

4.2

Engine .............................................................................................................................................................. 22

4.2.1

Preliminary instructions ................................................................................................................... 22

4.2.2

Bleeding fuel lines ........................................................................................................................... 22

4.2.3

Valve clearance ............................................................................................................................... 22

4.2.4

Replacing fuel filter .......................................................................................................................... 22

4.2.5

Replacing oil filter ............................................................................................................................ 22

4.2.6

Readjustment V-beltplacing oil filter ................................................................................................ 23

4.3

Regular maintenance ....................................................................................................................................... 23

4.3.1

Maintenance schedule ..................................................................................................................... 24

4.3.2

Putting out of service ....................................................................................................................... 25

5 TROUBLE SHOOTING .................................................................................................................................................. 26

5.1

Alternator/ electrical faults ................................................................................................................................ 26

5.1.1

General ............................................................................................................................................ 26

5.1.2

Trouble shooting table ..................................................................................................................... 26

5.2

Engine faults ..................................................................................................................................................... 27

5.2.1

General ............................................................................................................................................ 27

5.2.2

Trouble shooting table ..................................................................................................................... 28

5.2.3

Warnings ......................................................................................................................................... 30

5.2.4

Service address ............................................................................................................................... 30

5.3

Special procedures alternator ........................................................................................................................... 31

5.3.1

Residual voltage check / excitation procedure ( M-SQ8 only) .......................................................... 31

5.3.2

Testing rotary rectifier diodes .......................................................................................................... 31

5.3.3

Winding resistant values .................................................................................................................. 31

5.3.4

Meggering ....................................................................................................................................... 31

5.4

Special procedures engine ............................................................................................................................... 31

5.4.1

Setting the RPM .............................................................................................................................. 31

5.4.2

Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 32

5.4.3

Measuring exhaust backpressure .................................................................................................... 32

5.4.4

Disassembling instructions .............................................................................................................. 33

6 SPARE PARTS LIST ..................................................................................................................................................... 34

MAINTENANCE LOG ............................................................................................................................................................... 36

EN / M-SQ8 & 10 / January 2010

3

INTRODUCTION

1 INTRODUCTION

1.1 GENERAL

The M-SQ8/10 Marine Diesel Generating set is manufactured and marketed by Whisper Power .

It is important to read this manual before installing and operating the generating set. Both safety and durability rely very much on the correct identification, installation and a good understanding of ratings, features, design, maintenance and operation procedures.

The information, specifications, illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press.

All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the M-SQ8/10 generating set.

This manual is valid for the following models:

Part Description number

41106005 M-SQ8 230V 1500rpm

41106006 M-SQ8 230V 1500rpm -ungrounded

41109005 M-SQ10 230V 1500rpm

41109006 M-SQ10 230V 1500rpm -ungrounded

For other models see other manuals available on our website: www.whisperpower.eu.

Our policy is one of continued development and we reserve the right to amend any technical information without prior notice.

Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer, distributor, or dealer in any circumstances 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 which, if not strictly observed, may result in electrical shock which will result in severe personal injury or loss of life.

4


1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be carried out according to the directions in this manual. For service and maintenance one can appeal to the manufacturer or the dealers.

1.3 GUARANTEE

Whisper Power 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 well functioning of this generating set is subject to guarantee. The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries for the North of the Netherlands number 01120025 and are available on request. The guarantee period is two years, limited to 1000 running hours. Some aspects of our guarantee scheme are given here in more detail:

Guarantee does not cover failures that are caused by misuse, neglect or a faulty installation.

Example 1. Faulty installation:

Seawater entering the engine is the most common cause of damage to combustion engines in boats (both to propulsion and generator engines). The entry of water must be avoided under all conditions. Be aware that the conditions in blue water sailing can be extreme. Refer to the installation manual for instructions but remember these are for guidance only as many factors influence the installation of a generator. The ultimate responsibility will always be with the owner to ensure a safe and compliant installation. If in doubt ask!

DAMAGE CAUSED BY THE INGRESS OF

WATER IS NEVER COVERED BY

GUARANTEE

Example 2: Misuse:

Long term running with no load or too little load can cause the exhaust to get choked with soot or carbon. Cleaning the exhaust is not covered by guarantee.

Example 3: Neglect

Sometimes the seal of the raw water pump starts leaking.

Mostly this begins with a little drip and slowly gets worse.

Regular visual inspection of the generator is necessary to

prevent damage to occur from a leaking water pump.

When one find serious damage after weeks of neglect guarantee claims will not be honoured.

Example 4: Neglect

Whisper generators have an option for an auto start/stop mode or interval mode.

Whisper Power cannot be held responsible for damage caused by the unattended running generator.

Guarantee means that faulty parts are repaired or replaced free of charge. If necessary the whole generator unit will be exchanged. Labour necessary to complete repairs on board a vessel executed by an authorized service engineer is covered, but is limited to a reasonable number of hours and reasonable rates in relation to the actual repair work that has to be done.

Travel expenses and travel hours are not covered. Also not covered is the labour required to take a generator out of a boat or for 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 guarantee 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 covered by guarantee a credit will not be issued. For example if a

Printed Circuit Board is returned with clear damage caused by seawater, 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 off shore areas any additional costs incurred over normal carriage will be invoiced to the customer.

The cost for returning faulty goods is not covered under guarantee.

If any problem arises which could be subject of guarantee, procedures should be followed as described in the guarantee conditions, unauthorised repairs could lead to further damage and violate the guarantee conditions.

Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this user’s manual and the supplementary installation 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 spareparts only!


INTRODUCTION

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 be avoided by additional measures. Whisper Power does not accept liability for damage due to use of the generator, possible errors in the manuals and the results thereof.

Automatic start/stop

Whisper Power cannot be held responsible for damage caused by the unattended running generator using the auto-start/stop mode or interval mode.

5

INTRODUCTION

1.5 IDENTIFICATION

1.5.1 General

Before using this generating set it is very important to identify the set correctly. To communicate for service or ordering parts it is also essential to correctly identify the generating set. Also for the daily operation of the generating set it is necessary that the operator knows the correct specifications.

All required identification data are on the identification plate. For location of the identification plate see figure 1.

Fig. 1: Location identification plate.

1 The identity of the generating set is given by the

SERIAL NUMBER.

When this number is available the manufacturer can trace the specifications of the generating set. On the identification plate are also some basic features of the set:

2 POWER

The identification plate gives the nominal maximum continues load in kVA (= kW) calculated with power factor one. When calculating a load one should always take into account the power factor or cos phi of this load. The power should never exceed the nominal power as shown on the identification plate.

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

1500 rpm.

5 CURRENT shows the maximum current that is acceptable at the specified frequency, voltage and power factor.

6 WEIGHT shows the net dry weight (approximately) in kg. This is without fuel, oil, packing and external installation equipment

7 CE-marking: the “CE” symbol shows that the generating set is build according to European

Community safety regulations. This includes the regulations regarding the safety of pleasure craft, safety of machinery, electric safety and electric magnetic compatibility (EMC) and other relevant directives.

Safety also relies on the installation, application and circumstances. See also the remarks in this manual under

SAFETY

Before changing a factory setting you are advised to consult the manufacturer. When the generating set you have to identify is not new you have to take into account the possibility that former users may have changed the settings. Check the settings (voltage, frequency, rpm) when there is any doubt.

6


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 aware of wet conditions and hazardous environments caused by explosive gases etc

The voltage of 230 Volt generated by this generating set is dangerous and if instructions and procedures are not strictly observed may result in electrical shock which will result in severe personal injury or loss of life.

• Check all wiring at least once a year. Defects, such as loose connections, burned cables etc. must be repaired immediately.

• Do not work on the electrical system if it is still connected to a current source. Only allow changes in your electrical 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.

Warning signs indicate parts which could be live.

INFORMATION

2.1.3 Earth insulation failures

According to local regulations and depending on the application it could be necessary to take measures for protection against 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 standard the

“neutral” and “ground” should be connected on the generating set.

Be aware that insulation protection systems can be different for different applications and even within the ship there could be different standards for different spaces. We did refer to the Recreational Craft Directive that applies to pleasure craft up to 24 m of length. Sometimes one has to comply with other standards such as the rules of certification societies like Lloyds Register of Shipping or

Veritas, regulations for the protection of personal, building legislation, etc. It is of the greatest importance to have expert advice on this issue.

In all situations the transfer switches between shore, inverter and generator should switch both neutral and L1. Of course this is the case when using a Mastervolt Masterswitch.

2.1.4 Installation

Whisper generating sets are not self contained and have to be properly installed in enclosed areas such as a machine room.

Installation includes measures to be taken to outlet exhaust fumes which contain carbon monoxide and are extremely dangerous.

Carbon monoxide (CO) is an invisible odourless gas.

Inhalation produces headache, nausea or death.

Installation includes measures for proper ventilation, safe electric connections, safe installation of the starting battery, proper fitting of the cooling system and fuel pipes etc. Refer to the installation manual.


7

INFORMATION

2.1.5 Operation

External moving parts like fans and V-belts are covered by the soundshield and therefore the M-SQ8/10 is very safe when the soundshield is closed.

Nevertheless take note of the signs on the generating set which show symbols in a triangle indicating danger.

When service has to be carried out while the engine is running, be aware of moving parts like V-belts.

• The generating set should be operated by authorised personnel only.

• Be aware of hot parts and especially parts of the exhaust system and the cooling 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 manual before carrying out maintenance.

•

Do not change the settings without consulting the manufacturer. Keep a record of setting changes in this manual.

2.1.6 Fire and explosion

Fuels can be flammable. Proper handling limits the risk of fire 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.

8

BREAK

THROUGH

HERE

FIRE EXTINGUISHER PORT :

IN CASE OF FIRE, DO NOT OPEN SOUNDSHIELD.

TO AVOID SERIOUS INJURY OR DEATH FROM FIRE

SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.

IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS

PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.

Fig. 2: Fire extinguisher port.

• In case of fire do not open the soundshield. To avoid serious injury or death from fire, shut down engines, generator sets and blowers. Break through the label which is indicated by BREAK

THROUGH HERE and then immediately discharge entire contents of gaseous portable fire extinguisher through the fire extinguisher port. On the generating set this fire extinguisher port is indicated by the label as shown in figure 2.

• Poor electrical connections or using wiring which is not suited for the rated currents can cause overheating and possibly fire.

2.1.7 Chemicals

• Fuels, oils, coolants, and battery electrolyte can be hazardous to personnel if not treated properly.

Do not swallow or have skin contact with these liquids. Do not wear clothing that has been contaminated by fuel or lubricating oil.

• Gaskets may be manufactured from asbestos.

Particles of this material should not be inhaled as this may result in fatal diseases.

• On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter the blood stream with fatal results.

• Engines may be fitted with seals or O-rings manufactured from "viton" or similar material.

When exposed to abnormal high temperatures in excess of 400°C an extremely corrosive acid is produced which cannot be removed from the


INFORMATION skin. If signs of decomposition are evident, or if in doubt, always wear disposable heavy duty gloves.

2.2 TRANSPORT, LIFTING AND STORAGE

When lifting the generating set avoid any risk of personal injuries, do not stand under the generating set.

•

Use soft slings to avoid damage

• On the engine are two hoist eyes which can be used to take the generator out of the capsule.

They can also be used to lift the complete generating set including the capsule.

• After transporting the generating set check for damage before installation.

• Long term storage can have detrimental effects on engine and alternator. The engine should be put through an engine preservation procedure.

(Refer to the maintenance chapter)

• The alternator windings tend to condense. To minimise condensation, store the generating set in a dry and warm storage area.

• After removing the generating set from long term storage perform an insulation check. (Refer to the alternator maintenance paragraph for procedures)

•

While the battery is stored it should be recharged every 12 weeks.

2.3 THE

2.3.1 Features

This generating set includes 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 materials.

Installation accessories are listed in the installation manual and are available through the supplier of the generating set. The full automatic Digital Control is based on microprocessor technology. Several automatic start/stop functions can be programmed and monitored (refer to

Digital Diesel Control users manual).

2.3.2 Remote control

The full automatic remote control panel including 15 mtr cable comes as standard with the Whisper generating set.

2.3.3 Documentation

Included in the delivery is:

•

This users manual (number: 40200221 )

•

An installation manual (number: 40200401 )

•

A users manual for DCC (number: 40200261).

• A quick reference guide for DDC (number

40200275)

Not included in the standard delivery but available as options are:

•

Parts manual; number: 40200185

•

Workshop manual; number: 40200172

However in this manual there is a list of important parts for maintenance and spare parts as well as a chapter on maintenance and problem solving.

2.3.4 Accessories included in the standard delivery

• Special hose connector for measuring exhaust backpressure

•

Expansion tank, hose and fittings


9

INFORMATION

2.4 COMPONENTS

2.4.1 Main components to identify

exhaust bend

03 Exhaust manifold (watercooled)

04 Starter motor solenoid

07 Rubber engine mounting

Fig. 3 Front View main components M-SQ8 and 10

08 Bypass cooling water in

10 Bypass cooling water out

13 AC power output

14 Power take off (PTO)

15 Injection pump air bleeding screw

16 Hoist eye front

17 Fuel injection pump screw

19 Fuel solenoid ( M-SQ8 )

20 Electronic governor ( M-

SQ10 )

22 Engine oil filter

23 Fuel lift pump

24 Oil sump hand pump

Fig. 4: Rear view main components M-SQ8 and 10 .

10


Fig. 5: Rear view main components M-SQ8 and 10

INFORMATION

(DDC)

26a Identification plate

27 Fuses

27a Air cleaner element

28 Fuel injector (3x)

30 V-belt

31 Engine coolant pump

33 Engine serial number

34 Filler cap engine oil

40 Coolant drain plug

41 Engine oil pressure switch

42 Engine oil dipstick

43 Hoist eye rear

44 Filler cap engine coolant

46 Filler cap engine oil

49 Failsafe

50 Rubber engine mounting

Fig. 6: Top View main components M-SQ8 and 10


11

INFORMATION

2.4.2 Generator control panel

Internal fuel pump

Fuse 3A

Digital Diesel Control

Fuse 3A

Remove fuse before maintenance

Auxiliary

Fuse 10A

Fig: 9 Control panel.

Start / Stop

External Fuel Pump

Fuse 3A

Whisper Digital Diesel Operation Unit

Observe instructions in the manual

Replace fuses with same type and rating

Fig. 10 Digital Diesel Control unit

6 5 1 2

7

6 Generator load indicator.

7 Display

4

Fig. 11: Digital Diesel remote control panel

2.4.3 Remote control panel

1 Start button;

3

2.5.1 AC alternator

The single phase alternator is directly coupled, one bearing, brushless, rotating field design, four poles (1500

RPM) and self regulating.

Residual magnetism causes a small voltage over the stator windings and allows a current to flow in the windings, which is magnified because of the feed back effect between rotor and stator. The field windings in the rotor are short-circuited over a diode to rectify the current.

A capacitor over an additional winding in the stator which is at an angle with the power-winding keeps the voltage stable within 5 % at the specified rpm and provides voltage fall off with speed, preventing over-excitation at low engine speeds and softening the effect 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.

2.5.2 Engine

The M-SQ8/10 generating set is based on the Mitsubishi

S3L2 3 cylinder diesel engine. The engine is indirectly injected. The engine is water cooled and the cooling liquid is cooled by a heat exchanger and raw water. The heat exchanger and all other parts which are in direct contact with the raw (sea) water are made of seawater resistant material like naval brass and gunmetal.

The engine has been specially adapted for the Whisper

Power application and is very different from the standard engine supplied for industrial applications!

The M-SQ10 is almost identical to the M-SQ8 . The only difference is the electronic governor on the M-SQ10 .

Because of this electronic governor the M-SQ10 brings 2 kW more power than the M-SQ8 .

2.5.3 Digital Diesel Control system

The standard electrical engine control system is 12 Volt negative earth, non earth return (ungrounded) is available as optional. Check your 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 the alternator

2.5.4 Battery charger

On the engine is an alternator generating 50 Amp 12V.

This current is rectified to charge the battery. The voltage is regulated at ±14.4V.

12


2.5.5 Alarms and shut down

In the event of malfunctioning this will be indicated by the failure light, details will be shown on the display and the engine will be shut down. There are three functions guarded: oil pressure, oil temperature and exhaust temperature.

Exhaust temperature too high indicates the cooling water to be blocked.

All alarm switches are closed when no malfunction occur.

A contact is cut in the event of an alarm. This means that the generating set will not work when the alarm switches are broken or there is a loose wire. The system therefore is intrinsically safe. The panel will display details about the alarm.

2.5.6 Control

The generating set can be operated by push buttons on the panel on the alternator or by the remote control. By pushing the START button the control system is activated and will start the engine automatically. Pushing the STOP button will stop the engine and the electrical system will be deactivated.

2.5.7 Remote control

All wiring connections from the remote control to the board are made by plug in connectors.

An intermediate communication cable is in the standard supply. If necessary an optional longer 8 wire communication cable can be connected if the standard length does not suit the required distance. Numerous remote control units can be put in parallel by using the connectors on the back of 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.

The engine must only be used with diesel 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 Mitsubishi engine must


INFORMATION 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 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.

We recommend a multigrade oil 15W40.

Excluding the oil filter the content of the crankcase is

3.7 l. Including the oil filter it is 4.2 l.

Do not overfill with lubricating oil as this may have a detrimental effect on engine performance

4 Oil pressure

•

Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar).

• Normal at 1500 rpm ±350kPa (3.5 kgf/cm² - 50 psi) (3.5 bar).

2.5.12 Cooling liquid

The engine is cooled by cooling liquid. The capacity of this system of the M-SQ8/10 is 3.5 litres.

We recommend not using water but cooling liquid that is marketed for the use in combustion engines. Cooling liquid protects the engine against frost to minus 25° C. Also it protects the engine block against corrosion. One can fill the engine via the filling cap on the exhaust manifold. Fill up till the level is just below the filling cap. When the engine is on temperature the liquid will expand and the redundant liquid will be pressed into the expansion tank.

This tank has to be filled up till the mark. When 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. When the cooling is based on keel cooling or radiator cooling the capacity of these coolers and piping has to be taken into account calculating the right mixture.

The cooling liquid in the engine is pressurised and has a boiling point above 100° C. The temperature switch in the thermostat housing switches at 110° C. When keel cooling or radiator cooling is applied the cooling system is not pressurised. There should be a special cap on the manifold without valves leaving the connection to the expansion tank open. Refer to the manual on keel cooling and radiator cooling.

13

INFORMATION

GENERAL

Model

RPM

Alternator

Engine

Number of cylinders

Displacement

Bore X stroke

Combustion air consumption

Continuous power engine

Cooling system

Cooling water pump

Fuel lift pump engine

Starting battery (optional)

Fuel consumption

Control

ELECTRICAL SPECIFICATIONS

Output voltage

Output rating M-SQ8 :

Output rating M-SQ10 :

Voltage tolerance

Frequency tolerance

Alternator

Voltage regulation:

MECHANICAL SPECIFICATIONS

Supply includes

Dimensions hxwxd

Colour

Weight

Max. installation angle

Standard supplies

Optional:

M-SQ8/10

1500 water cooled, synchronous

Mitsubishi diesel, model S3L2 (Japan)

3

1318 cm3

78x92 mm

1.3 m³/min.

M-SQ8 : 8 kW; M-SQ10 : 10 kW indirect cooling by raw water, 18-22 l/min.

PTO driven Whisper Power self priming impeller pump, type M12 electric pump (12 V DC), additional pump available upon request

85 Ah 12V

2-4.5 litre/hour, load dependent

Digital Diesel Control including automatic start/stop

230V 50 Hz alternating current (AC) single phase

8 kVA = 8kW at power factor cos phi = 1

10 kVA = 8kW at power factor cos phi = 1

± 5%

M-SQ8 : ± 5%; M-SQ10 : ± 1% brushless, four pole, synchronous

Capacitor

Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator set without sound shield is optional)

635 x 900 x 575 mm top white, bottom green

340 kg including sound shield

25 degrees

Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals

Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part kits, PTO to drive a hydraulic pump

14


2.5.14 Wiring codes and colours

battery > starter motor starter motor > DDC starter motor > LCP battery > ground ground > LCP ground (GND)

DDC > glow plug

DDC > starter solenoid

LCP > fuel lift pump +

LCP > fuel lift pump –

DDC > LCD

DDC > oil pressure switch

LCP > oil pressure switch

DDC > water temperature switch

LCP > water temperature switch

DDC > exhaust temperature switch

LCP > exhaust temperature switch

DDC > fuel solenoid (hold)

DDC > fuel solenoid (pull)

DDC > fuel solenoid (com.)

B+ terminal alternator > starter motor

DDC >R terminal alternator

DDC > L terminal alternator

DDC > current measuring transformer

DDC > current measuring transformer

DDC > LCP

DDC > LCP

DDC > LCP

DDC > generator AC output

DDC > generator AC output

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

19

11

11

12

14

16

33

33

7

8

8

9

20

17

21

18

5

6

6

7

3

4

5

15

number

1

13

2

INFORMATION blue/black blue/green blue/pink green pink black red white orange black red black red red/green brown blue

colour

red red red black black brown yellow grey black grey purple purple/black blue

1 mm2

1 mm2

1 mm2

1,5 mm2

1,5 mm2

1,5 mm2

6 mm2

1,5 mm2

1,5 mm2

1 mm2

1 mm2

1,5 mm2

1,5 mm2

1,5 mm2

1 mm2

1 mm2

cross section

25 mm2

6 mm2

2,5 mm2

25 mm2

4 mm2

4 mm2

2,5 mm2

1,5 mm2

1,5 mm2

1,5 mm2

1 mm2

1 mm2

1 mm2


15

INFORMATION

2.5.15 Lay out control wiring

Fig 12: Electrical Diagram control wiring M-SQ8 and 10

16


2.5.16 Electrical diagram 230 V AC / 50 Hz

STATOR

GREEN (1)

EXCITATION

WINDING

GREEN (2)

ROTOR

CAPACITOR

INFORMATION

RED (3)

MAIN WINDING

EARTH AND NEUTRAL NOT CONNECTED

230V / 50Hz

RED (11) BLACK (11)

DDC/ct-1

BROWN

L1

BLACK (4)

RED (3)

YELLOW/GREEN

PE

BLUE N

MAIN WINDING

DDC/AC-1

BLACK (4)

YELLOW/GREEN

EARTH AND NEUTRAL CONNECTED

Fig. 13: Electrical diagram 230V


17

INFORMATION

2.5.17 Diagram electronic governor M-SQ10

The M-SQ10 is equipped with an electronic governor in addition to the mechanical governor that is on other

Whisper models. A governor keeps the speed

(RPM=Rotations Per Minute) of the engine at a fixed value. The RPM of the engine correlates with the frequency of the electrical output (1500 RPM =50 Hz) of the alternator.

Under full load the RPM of the Whisper models that has only a mechanical governor can drop 75 RPM (=2.5 Hz) at full load and will go further down or collapse when further loaded. However the engines with the electronic governor will keep the RPM and frequency at the set value. As the voltage is related to the frequency, the voltage will be more stable as well.

The RPM represents power and the alternator performs better as well on a higher speed. Whisper models with an electronic governor will bring more power.

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 and other mechanical transmissions.

2 A microprocessor keeps the speed at the set value by controlling the actuator. The microprocessor is programmed at the Whisper Power factory and many parameters are set to perform well. It should not be necessary to make adjustments. When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor.

The Whisper Power electronic governor does not need a pickup device in the flywheel housing that counts the passing tooth of the flywheel and determines the exact

RPM of the engine, because the processor uses the 50 Hz of the AC output voltage as a reference.

(When this manual was not supplied with the generator and there is a pick up on your generator than you have another model than referred to in this manual.

Refer to our website for the correct manual.)

Fig 14: Diagram electronic governer

18


OPERATION

3 OPERATION

3.1 GENERAL

The generating set is operational after full installation and filling up with: fuel, engine lubricating oil and cooling liquid, connecting the battery to earth and connecting the digital remote control panel.

1 Maximum oil level

2 Minimum oil level

Fig. 15:

1

2

3.2.1 Summarised operating instructions (daily use)

Routine "pre-start" checks:

1 Check oil level (refer to fig. 15).

2 Water inlet (all valves open).

3 Power source selector switch (off/shore power/generator power). Switch to power source switch "OFF", or switch off all consumers in the usual way. If a MASTERSWITCH is installed, this operates automatically.

4 Switch on battery switch (when installed).

5 Fuel valve: open.

Starting:

Push the start 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 generating set up to maximum, have it run warm. Continuous load should be restricted 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 Close the inlet sea water cock.

4 Switch to an other AC power source, if available. If a

Masterswitch is installed, this is done automatically.

3.2.2 Extended operating instructions

Check when starting the first time or after a longer period of rest:

1 If there is any damage caused by transport or installation.

2 Check if the installation conforms to the installation instructions.

3 Ensure the generating set is free to turn without obstruction.

4 Check all hoses and hose connections for leaks.

5 Check all cables and cable end terminal connections.

6 Check the engine and generator mounting bolts.

Routine "pre-start" checks:

1 Check engine oil level.

The generator switches off in the event of insufficient oil-pressure. Even when the oil level is too low the oil pressure can be high enough. Do not run the generator with the oil below the lowest mark in the, because a smaller volume of oil will become contaminated considerably quicker than a larger volume. Therefore we recommend daily oil-checks.

Check oil level prior to starting the engine or at least 5 minutes after the engine has stopped.


19

OPERATION

2

3

4

7

Check sea water cocks. Do not forget the valve of the water outlet in case of a water/exhaust gas separator.

Check the water strainer.

Check for leaks.

5 Regularly check the siphon vent in the cooling water supply.

6 If no MASTERSWITCH is used: Switch main Power

Source Selector switch to "OFF" or switch off all devices.

Switch on the battery switch.

Starting the generator:

By pushing the start button briefly the electric system is activated, the fuel lift pump starts pumping and the starting procedure will begin (by pushing the Stop button the system is deactivated).

The first time starting up or after running out of fuel it could be 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 process, the cooling water pump is driven with the engine. The cooling water is discharged to the exhaust outlet, because the engine does not run, the exhaust pressure is not high enough to expel this water.

Open the valve directly when the engine starts to prevent damaging the impeller.

Water in the cylinder will cause serious damage to the engine. For instance; a bent piston rod or a cracked cylinder head. In fact water in the cylinder is the main cause for engine damage in pleasure craft.

Checks once the generator is in operation:

1

2

3

Check for abnormal noise or vibration.

Check the voltage.

Check coolant flow.

Always check immediately after starting the generator if cooling water flows at the exhaust outlet. If this is not the case, check the cooling water pump. After having become acquainted with the generator you will be able to recognise the coolant flowing through the system by listening for the noise of the water which is expelled.

Be aware that especially in harbours the coolant water inlet can easily be blocked by floating objects.

4 Power source selector switch (off/shore power/generator power). Switch to power source generator. If a MASTERSWITCH is installed, this operates automatically.

Before loading the generating set up to maximum, have it run warm. The first 50 hours of running the continuous load should be restricted to 70 % of maximum load. Running for long periods at no load or light load in the first 50 hours can cause cylinder glazing and high oil consumption.

Engine load during longer operation:

Please ensure that the generating set is not overloaded.

Overloading occurs when the electrical load (demand) is so high that the generator cannot be turned around properly by the diesel engine. Overloading causes the engine to run rough, while using oil and excessive fuel and producing soot by the exhaust. The engine can even stop.

The generator should therefore only be loaded at the maximum rated 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 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 M-SQ8/10 is designed so as not to overheat, even under extreme conditions.

Do not run the generator for very long periods at no load or at very low load. When this is necessary do load the generator at least one hour in 10 hours for minimum 70%.

Long term running at too low load will cause the exhaust to be choked by carbon.

Never remove 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

20


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:

Prior to switching off the generating set, decrease the generator load (i.e. turn off most electrical users) and let the generator run at low load for approx. 5 minutes to allow the engine to get properly cool (the influent sea water must flow through the system in order to cool the engine).

If the generator is operating in a hot environment and you do not act as given above, the excessive heat in the engine can trip the "high temp" alarms. In that case, a restart of the engine is not possible for some time. It is also recommended to switch off electrical users prior to stopping the generator because of the voltage drop that occurs as the engine comes to a halt. Such voltage drops may cause damage to electric motors, compressors (in refrigerators or air conditioners etc.).

2 Press the STOP button.

3 Close the inlet sea water cock.

4 Switch to an other 230V power source, if available. If a Masterswitch is installed, this is done automatically.

If the engine is not running and ‘failure’ and

‘charging’ LED is blinking, reset by stop button, otherwise it will drain the start battery

OPERATION


21

MAINTENANCE

4 MAINTENANCE

4.1 ALTERNATOR

The alternator does not require any maintenance. Periodic inspection and cleaning is recommended, depending on environmental conditions.

However when the alternator has been idle for a long period attention to winding condition is recommended.

The condition of windings can be assessed by measurement of insulation resistance to earth.

The CAPACITOR should be disconnected during this test.

A 500V ‘megger’ or similar instrument should be used. The insulation resistance to earth of all windings should be in excess of 1.0 MOhm. Should the insulation resistance be less than this value, drying out the generator windings is essential. Drying out can be carried out by direct warm air from a fan heater or similar apparatus into the generator air inlets or outlets.

All bearings are greased for life and not regreasable.

4.2 ENGINE

4.2.1 Preliminary instructions

All regular maintenance can be carried out when the enclosure is open. When oil and dirt has gathered in the enclosure measures have to be taken to avoid spilling oil and polluting the environment.

The first service on the engine should be carried out after

50 hours of its life and after a major 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 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 fuel system. Push the start button activating the electric system and activating the fuel pump. When more time is needed to bleed, push “start” and hold on the local control panel (so not on the remote panel) Hold as long as necessary to bleed the system.

Retighten the bleed screw when no further air bubbles are expelled.

1

Fig. 16: Bleeding fuel lines 1 = Fuel bleeding screw

When the engine is in cold condition both valves (inlet and outlet) should have a clearance between 0.25 mm. The adjustment has to be done at TDC (refer to § 5.4.2).

4.2.4 Replacing fuel filter

Filter change depends on contamination of the fuel, but should be done however, at least every 300 running hours.

Before changing the filter, clamp off the supply line.

Remove the hoses from filter and attach them on the new filter again. The arrow on the filter housing indicates the direction of the flow. A clogged filter results in a lack of output of the generating set.

4.2.5 Replacing oil filter

The oil filter is in front of the service side. Replacement has to be executed according to the schedule in this manual. Drain the oil using the sump pump and put some tissues under the filter.

Fig. 17

22


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.

Fig. 18

The alternator bracket allows for readjust of the V-belt.

Deflections should be 10 mm (refer to fig. 19)

Fig. 19

4.3 REGULAR MAINTENANCE

CHECK DAILY:

•

Oil level (see fig. 20)

Take care the oil level is never below the mark. Do not add oil when the level is still above the mark

1 Minimum oil level

2 Maximum oil level

Fig. 20:


10 mm

1

2

MAINTENANCE

CHECK DAILY:

•

Level cooling liquid

•

Hoses for loose connections or deterioration.

•

Water inlet filter.

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 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 with a dirty exhaust without investigating the cause as this may result in an expensive breakdown.

• Check air vent on a regular basis. When the air vent it not working properly the engine can fill up with water by siphoning. Water in the combustion chamber causes serious damage to the engine.

•

Check and readjust V-belt.

•

Check the electrical connections.

EVERY 150 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

• Check impeller raw water pump (durability depends on the purity of the sea water. In sandy water and warm water wear will increase).

When replacing the impeller the gasket between the pump case and the cover should be replaced as well. So when ordering a spare impeller order a gasket as well. Remove the cover to get access to the impeller. Remove the old impeller with the help of two screwdrivers. Install the new impeller and add some grease. Turn the blades in the direction of rotation of the pump i.e. anti clockwise looking at the impeller.

23

MAINTENANCE


•

Replace the impeller of the raw water pump.

• Retighten the cylinder head bolts and adjust the valve clearance. (Refer to § 5.4.2).

•

Replace the oil filter.

•

Replace the fuel filter

Replacement depends or the condition of the fuel. We recommend replacement every 300 hours. Isolate the fuel supply and change the element.


•

Replace the V-belt.

• Retighten cylinder head bolts/adjust + valve clearance.


•

Check lubricating oil pressure

• Clean and check or replace fuel injector nozzles and check injection pressure.

•

Check the air filter element:

The air is taken in via the cover on the alternator.

Below this cover is a spongy material which filters the air and holds some electrical components which are cooled by the inlet air. This filter does not require regular maintenance. Only in very dusty circumstances this filter should be cleaned.

The spongy material can be washed in solvent or replaced.

•

Check 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 could be cleaned by compressed air. When overhauling the engine one could clean the parts thoroughly or replace.

When the generator set runs less than 100 hours a year the oil should be changed yearly

Check oil level

Check water inlet filter

Check the level of the cooling liquid

Change oil and oil filter

Check and tighten nuts, bolts, etc.

Check exhaust

Check air vent


Check electrical connections

Change oil

Check battery

Check air vent


Check impeller water pump

Replace impeller water pump

Retighten cylinderhead bolts and readjust valve clearance

Replace oil filter

Replace fuel filter

Retighten cylinderhead bolts , adjust valve

Replace the V-belt

Check lubricating oil pressure

Check injector and injection pressure

Check inlet air filter

Check cooling system daily daily daily after first 50 hours after first 50 hours after first 50 hours after first 50 hours after first 50 hours after first 50 hours

150 hours

150 hours

150 hours

150 hours

150 hours

300 hours

300 hours

300 hours

300 hours

1000 hours

2000 hours

2000 hours

2000 hours

2000 hours

24


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 the fuel suction pipe and fuel return and put them in a can with preservation diesel fuel. Start the engine and run the engine warm.

3 Drain the hot engine oil and refill with preservation oil.

4 Stop 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

MAINTENANCE 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 Protect the generating set against the influences of bad weather conditions.

This method of preservation will be sufficient for 6 months.

Repeat steps 2, 3, and 4, every 6 months. Change oil before using the engine again.


25

TROUBLE SHOOTING

5.1 ALTERNATOR/ ELECTRICAL FAULTS

Beware of parts which are live!

Remove 3 Amp. Fuse in the control panel

5.1.1 General

If any problem should occur, check basic conditions and

RPM (50 Hz) according to its settings and does as well under load.

•

M-SQ8:

A RPM drop of 5% at full load is acceptable. Therefore a no load setting should be at 1575 RPM = 52.5 Hz. Under no circumstances should the RPM under full load be below 1470

RPM = 49 Hz. while working on the generator to prevent the engine from starting

A failure code is displayed when a hardware failure at the generator is detected

•

M-SQ10:

A RPM drop of 1% at full load is acceptable. Therefore a no load setting should be at 1515 RPM = 50.5 Hz. Under no circumstances examine all external wiring, switch gear and circuit breakers. Also check if measuring instruments give the correct value. If in doubt, measure directly on the alternator terminals with an independent instrument. should the RPM under full load be below 1485

RPM = 49.5Hz.

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.

This should only be carried out by an experienced electrician. Check if the engine is running correctly at 1500

Failure code

COMMUNICATION

LOW START BAT

ALTERNATOR

EXHAUST TEMP

WATER TEMP

OIL PRESSURE

AC VOLTAGE

HIGH CURRENT

FREQUENCY

Problem

Communication error between the panel end the generator

Starter battery voltage too low

No output battery charging voltage

Exhaust temperature is too high

Coolant temperature is too high

Oil pressure failure

Generator AC output voltage is either too high or too low

Generator is in overload

Output frequency of the generator is too low

5.1.2 Trouble shooting table

PROBLEM CAUSE

No output (Voltage) at all

Generator output voltage too low when no load is on it (less than 210V/105V)).

• Circuit breaker "off" or faulty fuse

SOLUTION

Check switches and fuses and measure directly on the alternator to exclude external causes.

• Low engine RPM.

• Loss of residual magnetism.

• Capacitor loose or broken.

• Rotor diodes broken.

Check the engine RPM and adjust (refer to special procedures).

Check the residual magnetism and flash the alternator (refer to special procedures).

Check by independent excitation if the problem is in the capacitor or in the windings.

Check the diode in the rotor (refer to special procedures). The M-SQ8/10 has one diode in the rotor.

• No load at all or very low load.

Switch on a load and check voltage.

• Engine is not reaching the rated RPM.

Refer to special procedures to readjust RPM.

• Defective capacitor.

Check capacitor and replace if necessary

(refer to special procedures).

• Defective diode

Check the diode in the rotor and replace (refer to special procedures).

26


TROUBLE SHOOTING

PROBLEM CAUSE

Generator output voltage too low under load (less than

210V/105V).

In no load condition it is ok

Generator voltage too high,

(more than 245V/130V)

Generator voltage fluctuates.

SOLUTION

• Generator is overloaded. Switch off a load; (part off) consumers.

• Engine is not reaching the rated RPM. Refer to engine RPM problems

• Defective capacitor Check capacitor and replace if necessary

(refer to special procedures).

• Only

M-SQ10 : Defective electronic governor, actuator controlbox or pickup.

RPM will be too low as well

Replace faulty part

• Engine is running too fast (RPM too high).

Check engine speed and adjust (refer to special procedures).

• capacitors

• Presence of a strong capacitive load

(leading power factor)

• Disturbances on the electrical system/ user side.

• Engine runs irregularly.

Check capacitor specification and replace capacitors if necessary.

Compensate for this capacity and seek for experts advice ( Whisper Power customers service)

Check if electrical load is fluctuating

When engine runs irregularly refer to section:

"Engine runs irregularly".

Generator is not able to start an electric motor

If the generator is unable to supply enough power to start an AC electric motor, this is usually because this motor draws too much current during starting

Check the electric motor’s current draw required for starting. This should not exceed the rated 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.

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 relating to Voltage or Frequency are due to wrong engine speed. Note that RPM and Hz are basically the same. Use the problem solving table to find the cause of a wrong engine speed. When there is no obvious cause one can adjust the RPM (refer to special procedures). The engine speed of the M-SQ10 is controlled by an electronic governor should be within a tight tolerance of 1%. When not, this indicates the electronic governor to be faulty or need adjustment (refer to 2.5.17). When the engine is not cranking well, starting problems almost always originate from battery problems or poor battery cable connections. When the engine is cranking, well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes.

When the engine does not start instantly, prolonged cranking can fill up the exhaust system with cooling water because of the water injected exhaust. When the water enters the cylinder through the valves this will bring severe damage to the engine. When the engine does not start and repeated cranking is necessary shut off the seawater inlet. Open the valve immediately after the engine has started.

A failure code is displayed when a hardware failure at the generator is detected.

Failure code

COMMUNICATION

LOW START BAT

ALTERNATOR

EXHAUST TEMP

WATER TEMP

OIL PRESSURE

AC VOLTAGE

HIGH CURRENT

FREQUENCY

Problem

Communication error between the panel end the generator

Starter battery voltage too low

No output battery charging voltage

Exhaust temperature is too high

Coolant temperature is too high

Oil pressure failure

Generator AC output voltage is either too high or too low

Generator is in overload

Output frequency of the generator is too low


27

TROUBLE SHOOTING

5.2.2 Trouble shooting table

PROBLEM CAUSE

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 indicate “LOW

START BAT”

• One other possibility is that the engine is locked by water in the cylinder or there is other severe damage..

Starter is turning engine smoothly, but engine fails to start

Engine runs irregularly.

• Starter battery switched "OFF".

•

(battery too weak).

• Faulty fuse on the control panel

• Wiring control system faulty

• Starter broken

• To thick engine lubricating oil.

• Out of fuel or faulty fuel, water in the fuel.

• Fuel solenoid is not opening (no “click” can be heard).

• Fuel lift pump is not working.

• Fuel filter is blocked.

• Air in fuel lines.

• Wrong valve clearance.

• Low compression because of dirty valves.

• Blocked injector.

• Loss of compression by wear out or damage

• Unsuitable contaminated fuel

• Lack of fuel.

• Choked fuel filter.

SOLUTION

Check on water in the cylinder and further damage by cranking. When there is water in the cylinder, then deactivate the control system, disconnect the battery, remove the glow plugs.

Crank the engine to remove the water through the opening of the glow plugs. Check oil on the presence of water and change oil. Find out how the water did enter the cylinder (check the air vent). Take precautions to prevent it from happening again. When there is no mechanical malfunction the problem must be an electric malfunction.

Check position of the battery switch and switch

"ON".

Check battery voltage. Recharge the battery.

Inspect battery terminals and cables for a good electrical connection (inspect against corrosion, tattered wires, etc.)

Replace fuse

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.

Repair the starter motor

Change oil for a lower viscosity.

Fill up with fuel or replace with better quality.

Check wire connections and circuitry to solenoid.

(Refer to DC wiring diagram)

Check fuel filter and fuel lift pump: clean or replace if necessary.

Bleed air from fuel system (refer to maintenance section).

Adjust valve clearance,

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 removed. When the outlet port is strongly affected by rust, the exhaust system is not properly installed (refer to paragraph 5.4.3).

Contact Whisper Power service department for advice.

Have the injector tested and cleaned if necessary.

Repair by Whisper Power service

Fill up with fuel or replace by better quality.

Check fuel filter and fuel lift pump: clean or replace if necessary.

Check if electrical load is fluctuating

• Disturbances on the electrical system/ user side.

• Faulty fuel lift pump.

• Choked air filter.

• Lack of air.

• Choked exhaust system, exhaust blocked, rubber exhaust hose kinked.

• Air in the fuel pipes

Check and repair

Check the air intake

Check the exhaust hose

Bleed air from fuel system (refer to maintenance section).

28


TROUBLE SHOOTING

PROBLEM CAUSE

Engine speed drops

Engine does not stop on command

Engine exhaust smokes

Engine starts, but stops after 10 up to 30 seconds

Engine stops by itself

• Faulty electronic governor (

M-SQ10 only)

• Blocked injector.

Replace faulty parts.

Have the injector tested and cleaned if necessary.

• Wrong valve clearance. Adjust valve clearance.

• Temporarily hunting (this will disappear when engine has run in).

• Ongoing hunting caused by faulty electronic governor ( M-SQ10 only)


• Faulty electronic governor (

M-SQ10 only)


• Too much oil.

• Lack of fuel.

• Lack of intake air.

• blocked, rubber exhaust hose kinked.

Drain oil to proper level

Check fuel supply system: fuel pump and filter.

Check air intake.

Check the exhaust system.

• Generator overloaded Reduce the electrical load (switch off some consumers).

• Generator over energised. bearings or other)

Check that the proper capacitor type is installed and that it is connected correctly.

Generator must be sent to manufacturer for repair of damaged bearing or winding.

• Damaged engine

• Fuel solenoid is not switching off •

• Loss of control

Repair by Whisper Power service

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

• Faint blue smoke - generally the result of light load

Increase load.

• Heavy blue smoke - caused by lubricating oil: Overfull oil sump or worn cylinder bore, stuck broken or worn rings.

• Black smoke –incomplete combustion caused by: Overload, choked air filter, inlet temperature too high, unsuitable fuel or water in fuel.

Check the oil level.

Check the compression.

Check the fuel .

Check for overload.

• 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.

• Overload or short circuit.

• Lack of fuel.

SOLUTION

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.

Switch off the consumers and test for short circuit.

• Oil pressure low. (oil pressure switch tripped).

Check fuel supply system: fuel lines, pump, filter, valves, tank level, etc.

Check oil level.

Check engine’s oil pressure and have it repaired by Whisper Power .

Check cooling water system flow: water pump, inlet water filter, coolant flow.

• Excessive heat in cooling system

(thermo-switch tripped).

• Lack of cooling water (exhaust switch tripped).

• Impeller broken.

• Cooling water blocked.

• Water strainer blocked.

• Air or water in the fuel.

• Blocked air or fuel filter.

• Loss of compression by wear out or damage.

• V-belt broken or loose.

Repair by Whisper Power service.

Readjust or replace V-belt


29

TROUBLE SHOOTING

PROBLEM CAUSE

Sooty, black exhaust.

Loss of power

Over-temperature

• Faulty thermostat

SOLUTION

• Thermostat faulty

• Generator is being overloaded. Digital

Diesel Control will indicate “

HIGH

Check thermostat and replace

Check electrical load and switch off some consumers

CURRENT

”.

• Insufficient intake air.


• Fuel injector faulty.

• Valve clearance incorrect.

• Poor fuel quality.

Check intake air paths and filter, clean and replace if necessary.

Replace injector.

Readjust valve clearance

Use better quality diesel.

• Poor quality lubricating oil. Use better quality oil.

• Continuous running with very low load. Increase load and have the engine run for a few hours

● 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 appropriate instrument.

• Overfull oil sump.

• Choked fuel filter.


• Exhaust blocked.

• Injector blocked.

Bring the oil to the correct level

Replace the fuel filter.

Check air inlet openings; clean air filter.

Check the exhaust system.

Have the injector checked.

• Loss of compression, sticking 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.

• Overload.

• Low level of cooling oil or air in the cooling system

Take away the overload.

Fill up with liquid and release air bubbles. Check if there are air blocks in the system; refer to the installation manual

• Water inlet system blocked.

• Broken impeller.

• Water strainer choked

• Heat exchanger choked.

• Broken or slipping V-belt.

Check the cooling system thoroughly.

Replace and adjust the V-belt tension.

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 is on

If you cannot correct a problem with the aid of the malfunction table, contact your Whisper Power Service Centre or Whisper Power Netherlands, tel: INT+31-512-571550. www.whisperpower.eu.

30


5.3 SPECIAL PROCEDURES ALTERNATOR

5.3.1 Residual voltage check / excitation procedure ( M-SQ8 only)

When residual magnetism disappears there is no residual voltage. Residual magnetism can disappear after the generating set being out of service for a long period or a short circuit. This can be solved by charging the capacitor

("flashing") independently with a small 9 Volt battery. This can be done while the engine is stationary and the wiring is connected.

Fig. 21.

If the generating set battery is used for flashing one must take care. A short circuit can cause heavy sparking, fire and injuries

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.

DIODE

TROUBLE SHOOTING 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

If after establishing and correcting any fault on the capacitor and diode output is still low when separately excited, then the main rotor, stator and exciter stator winding resistance should be checked as the fault must be in one of these windings. The respective leads must be disconnected before taking the readings.

Resistance values should be within 10% of the values given in the table below:

M-SQ8/10

Resistance

• Resistance both main stator windings in series

• Resistance both rotor windings

• Resistance exciter stator winding

50Hz-230v

0.32 Ohm

2.6 Ohm

0.75 Ohm

5.3.4 Meggering

One can try to measure resistance between the housing and the windings with a multimeter which should read infinity. When readings are infinity but a fault 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

2

Fig. 22

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 reverse direction, and


Fig. 23 2 = adjustment screw 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.

31

TROUBLE SHOOTING

M-SQ10:

When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor. If readjustment of the RPM is necessary, please contact your Whisper Power Service Centre for advice.

M-SQ8:

Before readjustment check any other explanation for the wrong speed. Engine speed is set at the factory at nominal 1500 (50 Hz) RPM. A RPM drop of 5% at full load is acceptable. Therefore a no load setting should be at ±

1575 RPM = 52.5 Hz. Under no circumstances should the

RPM be under full load below 1470 RPM = 49 Hz. When no cause can be found for a wrong speed, the setting can be adjusted.

It is very important to identify the correct setting assembly

(refer to fig. 23). The screw is to be locked in position with the lock-nut.

5.4.2 Adjusting valve clearance and retightening the cylinder head bolts.

Both procedures have to be carried out with a cold engine.

When both procedures are carried out 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 drain plug (ref. to fig. 2).

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

(ref. to fig. 24).

Tightening torque cylinder head bolt:

Rocker stay tightening torque:

88 ± 5 Nm

14.7 ± 2 Nm

FRONT

MOTOR

8

6

4

1

2

3

10 9 11

Fig 24 Cylinder head bolts

Mark on timing gearcase

TDC mark piston 1

IT (injection timing) mark

7

5

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. 25).

First align the T.D.C. mark for 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.

After adjusting the valves of cylinder 1 adjust the valve clearance of the remaining cylinders in firing order 1 – 3 –

2. Turn the crankshaft 240 degrees clockwise from the

T.D.C of cylinder 1 to the T.D.C of cylinder 3. Adjusts the valves of cylinder 3 and turn the crankshaft further clockwise to the T.D.C of cylinder 2.

5.4.3 Measuring exhaust backpressure

The exhaust system must be of adequate size -2”/ 51 mm

- and maximal length (refer to installation manual). When any doubt; backpressure has to be measured. An easy way to measure for back-pressure is to use a water column. A water column can be made visible in a plastic tube along a yardstick and fitting the end to a hose connection to fit in the adaptor on the injection bent after removing the exhaust temperature switch.

MAXIMUM

69cm

27INCHES

TDC mark piston

2 and 3

Fig. 25

32

Fig 26: Measuring exhaust backpressure

The bent A hanging down should not be too short helping to damp the pulsating effect of the gas discharge that is


characteristic for a one cylinder engine. The water column should be no more than 27 inches (69 cm.) of water (1 PSI

- 0,07 bar)

5.4.4 Disassembling instructions

It could be necessary to disassemble the generating set for repair or checks. Following instructions will help:

1 The design of the M-SQ8/10 makes it possible to do most repairs on the spot. The heat exchanger is accessible and can be removed. The connections of the alternator are very accessible as well.

2 The sound shield canopy can be disassembled according to exploded view below (figure 27).

TROUBLE SHOOTING

3 To take the generating set out of the canopy all hose and cable connections have to be taken off. The set is fixed to its base by four rubber mountings and can be loosened by removing the four nuts from the bolts of these mountings. The easiest way to get the generator out of its capsule is by lifting the set with the aid of the lifting eyes.

4 Reassembling the generating set one should take care of alignment, cleaning the surfaces between engine and alternator and tighten the bolts crosswise and gradually.

5 Test the generating set first outside its capsule and check very carefully for leakages before putting it back in its enclosure..

Figure 27: exploded view sound shield M-SQ8 and 10


33

SPARE PARTS LIST

6 SPARE PARTS LIST

A complete parts manual in English is available as an option number: number: 40200185 (***)

A work shop manual in English is available as an option number: 40200172 (***).

We recommend the following spares for service and maintenance.

• Kit A: parts for regular maintenance parts marked (*)

• Kit B: parts for maintenance + spare parts: all parts marked (*)+(**)

• Kit C: parts for "world travellers" all parts marked (*)+(**)+(***) article no. 40201460 article no. 40201653 article no. 40201654

ARTICLE NO DESCRIPTION

40209030 Fuel filter (*)

50201060

50205120

40203121

50201450

Fuel lift pump (***)

V-belt (*)

Oil filter (*)

Raw water pump complete Whisper Power type M12 (***) (refer to fig. 28)

40209011

40201401

50209018

40201851

Impeller (50209013) + gasket (50209012) (*)

Cover type M12 (**)

Bolts cover (**) (6 pcs.)

Pump repair kit A consisting of: Shaft (50201811), Bearings (2 pcs) (50209014), O-ring (50209017),

Seals (2 pcs.) (50209015), Clips (1 set) (50209019), O-ring (50201814)

Pump repair kit B (**)(same as repair kit A excluding the shaft(5021811) and O-ring (50201814))

Heat exchanger complete with appendages (***)

40209010

50201413

50207022

50209132

50201890

50201482

50209140

40209161

50209200

50212170

50212154

50201423

40209102

50209133

50207033

50207030

50206040

50203050

50207060

50205045

50205038

Water hoses with clamps (**)

Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering)

Measuring coil (***)

Rotary diode (**)

Alternator bearing including O-ring (**)

Voltage regulator (optional)

Local control panel (***)

Digital Diesel Control Unit (***)

Fuses 10 Amps(*)

Fuses 3 Amps (*)

Wiring loom complete (***)

Digital Diesel Remote control panel (***)

Cable remote control 15 mtr, including connectors

Overhaul gasket kit / Seal kit (***)

Cylinder head gasket kit

Glow plug, 3pcs (**)

Nozzle injector, 3pcs (**)

Fuel pump (high pressure) complete (***)

Thermostat (**)

Gasket thermostat (**)

50207037 Gasket rocker cover (**)

More extensive parts list on the internet: WHISPERPOWER.EU

(fast moving parts)

34


SPARE PARTS LIST

Figure 28: Raw water pump complete Whisper Power type M12


35

MAINTENANCE LOG

MAINTENANCE LOG

first service after 50 hours: next service (every 150 hours): hour counter: hour counter:

36 remarks: remarks:


NOTES


NOTES

37

NOTES

NOTES

38


NOTES


NOTES

39

Kelvinlaan 82, 9207 JB Drachten, Netherlands

Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / [email protected]

User manual M-SQ 8, 10 ENG

USERS MANUAL

Marine diesel generating set 230V / 50Hz

Digital Diesel Control

CONTENTS:

1 INTRODUCTION

2 INFORMATION

BREAK

THROUGH

HERE

FIRE EXTINGUISHER PORT :

IN CASE OF FIRE, DO NOT OPEN SOUNDSHIELD.

TO AVOID SERIOUS INJURY OR DEATH FROM FIRE

SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.

IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS

PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.

3 OPERATION

4 MAINTENANCE

6 SPARE PARTS LIST

MAINTENANCE LOG

NOTES

NOTES

NOTES

Kelvinlaan 82, 9207 JB Drachten, Netherlands

Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / [email protected]

Related manuals

Table of contents

User manual M-SQ 8, 10 ENG

USERS MANUAL

Marine diesel generating set 230V / 50Hz

Digital Diesel Control

CONTENTS:

1 INTRODUCTION

2 INFORMATION

BREAK

THROUGH

HERE

FIRE EXTINGUISHER PORT :

IN CASE OF FIRE, DO NOT OPEN SOUNDSHIELD.

TO AVOID SERIOUS INJURY OR DEATH FROM FIRE

SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.

IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS

PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.

3 OPERATION

4 MAINTENANCE

6 SPARE PARTS LIST

MAINTENANCE LOG

NOTES

NOTES

NOTES

Kelvinlaan 82, 9207 JB Drachten, Netherlands

Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / [email protected]

Related manuals

Whisper Power

W-SQ 8

Whisper Power

W-SQ12

Whisper Power

M-SC3.5

Panasonic

EH-SQ10

Table of contents