USERS MANUAL FOR MOBILE APPLICATIONS
W-SQ20
- 1500 RPM -
Mobile diesel generating set 230/400V / 50Hz
Digital Diesel Control
Art.nr. 40200626
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
Nederland
Tel.: +31-512-571550
Fax.: +31-512-571599
www.whisperpower.eu
V1 April 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 ....................................................................................................................................................... 5
1.5.1
General.............................................................................................................................................. 5
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 W-SQ20 ...................................................................................................................................................... 9
2.3.1
Features ............................................................................................................................................ 9
2.3.2
Remote control .................................................................................................................................. 9
2.3.3
Documentation .................................................................................................................................. 9
2.4
Components ..................................................................................................................................................... 10
2.4.1
Main components to identify ............................................................................................................ 10
2.4.2
Generator control panel ................................................................................................................... 12
2.4.3
Remote control panel ...................................................................................................................... 12
2.5
Technical Information ....................................................................................................................................... 12
2.5.1
AC alternator ................................................................................................................................... 12
2.5.2
Engine ............................................................................................................................................. 13
2.5.3
Digital Diesel Control system ........................................................................................................... 13
2.5.4
Battery charger ................................................................................................................................ 13
2.5.5
Alarms and shut down ..................................................................................................................... 13
2.5.6
Monitoring ........................................................................................................................................ 13
2.5.7
Control ............................................................................................................................................. 13
2.5.8
Remote control ................................................................................................................................ 14
2.5.9
Hour counter .................................................................................................................................... 14
2.5.10
Load indicator .................................................................................................................................. 14
2.5.11
Fuel specification ............................................................................................................................. 14
2.5.12
Oil information ................................................................................................................................. 14
2.5.13
Cooling liquid ................................................................................................................................... 14
2.5.14
Technical data ................................................................................................................................. 15
2.5.15
Electrical diagram control wiring W-SQ20 ....................................................................................... 16
2.5.16
Terminal modes 115VAC – 230VAC - 400VAC 50Hz ..................................................................... 17
2.5.17
Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR .............................................. 18
2.5.18
AC Wiring Diagram single phase with AVR 230V Hz (Double Delta) .............................................. 19
2.5.19
Electrical diagrams radiator fan control ........................................................................................... 20
2
April 2010 / W-SQ20 for mobile applications / EN
CONTENTS
3
OPERATION .................................................................................................................................................................. 21
3.1
General ............................................................................................................................................................ 21
3.2
Operating Instructions ...................................................................................................................................... 21
3.2.1
Summarised operating instructions (daily use) ................................................................................ 21
3.2.2
Extended operating instructions ...................................................................................................... 21
4
MAINTENANCE ............................................................................................................................................................. 23
4.1
Alternator .......................................................................................................................................................... 23
4.2
Engine .............................................................................................................................................................. 23
4.2.1
Preliminary instructions ................................................................................................................... 23
4.2.2
Bleeding fuel lines ........................................................................................................................... 23
4.2.3
Valve clearance ............................................................................................................................... 23
4.2.4
Replacing fuel filter .......................................................................................................................... 24
4.2.5
Replacing oil filter ............................................................................................................................ 24
4.2.6
Tensioning V-belt............................................................................................................................. 24
4.2.7
Air cleaner element.......................................................................................................................... 24
4.3
Regular maintenance ....................................................................................................................................... 25
4.3.1
Maintenance schedule..................................................................................................................... 26
4.3.2
Putting out of service ....................................................................................................................... 26
5
TROUBLE SHOOTING .................................................................................................................................................. 27
5.1
Alternator/ electrical faults ................................................................................................................................ 27
5.1.1
General............................................................................................................................................ 27
5.1.2
Trouble shooting table alternator ..................................................................................................... 27
5.2
Engine faults..................................................................................................................................................... 28
5.2.1
General............................................................................................................................................ 28
5.2.2
Trouble shooting table engine ......................................................................................................... 29
5.2.3
Warnings ......................................................................................................................................... 31
5.2.4
Service address ............................................................................................................................... 32
5.3
Special procedures alternator........................................................................................................................... 33
5.3.1
Automatic Voltage Regulator (AVR) ................................................................................................ 33
5.3.2
Residual voltage check / excitation procedure (flashing) ................................................................. 33
5.3.3
Testing rotary rectifier diodes .......................................................................................................... 34
5.3.4
Winding resistant values.................................................................................................................. 34
5.3.5
Meggering ....................................................................................................................................... 34
5.4
Special procedures engine ............................................................................................................................... 35
5.4.1
Setting the RPM .............................................................................................................................. 35
5.4.2
Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 35
5.4.3
Disassembling instructions .............................................................................................................. 36
6
SPARE PARTS LIST ..................................................................................................................................................... 38
MAINTENANCE LOG ............................................................................................................................................................... 39
EN / W-SQ20 for mobile applications / April 2010
3
INTRODUCTION
1 INTRODUCTION
1.1
GENERAL
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.
The W-SQ20 Mobile 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.
DANGER
Realise that people are not used to have
230V/400V available on a vehicle. Put
warning signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
All of the specifications, provisions and instructions
contained in this manual apply solely to standard versions
of the Whisper Power W-SQ20 generating set.
This manual is valid for the following models:
1.2
Part number
41101020
Description
W-SQ20 230V 1500rpm
Mobile / keel cooling
41101026
W-SQ20 230V 1500rpm
Mobile / keel cooling -ungrounded
41101320
W-SQ20 230V/400V 1500rpm
Mobile / keel cooling
41101326
W-SQ20 230V/400V 1500rpm
Mobile / keel cooling -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.
4
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:
Overheating of the engine or alternator is the most
common cause of problems with mobile generating sets.
These problems are caused by poor circulation of the
cooling liquid due to wrong routing of the pipes to the
radiator: bents will capture air bubbles causing “air-lockes”
blocking the circulation of the liquid. Other examples of
installation problems are hot air circulation into the radiator
April 2010 / W-SQ20 for mobile applications / EN
INTRODUCTION
and the radiator fan sucking exhaust gasses into the
radiators.
The generator and other parts should be protected against
the influences of the weather and splashing water (with dirt
and salt) below the vehicle. 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!
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!
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.
1.4
Example 3: 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 vehicle or for reinstallation. There is no cover for
labour needed to get access to the generator, for example
to remove equipment or parts of the vehicle body 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 water, guarantee will be refused.
Freight costs to deliver spares by normal mail or carriers is
covered under guarantee. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote areas any
additional costs incurred over normal carriage will be
invoiced to the customer.
The cost for returning faulty goods is not covered under
guarantee.
EN / W-SQ20 for mobile applications / April 2010
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.
1.5
1.5.1
IDENTIFICATION
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.
5
INTRODUCTION
1.5.2
Identification plate
All required identification data are on the identification
plate. For location of the identification plate see figure 1
1
2
3
4
5
6
7
Fig. 1: Identification plate.
Fig. 2: Location identification plate.
6
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:
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 25ºC.
For higher temperatures the generating set has to be
derated. To drive the radiator fan (230 V fan) output
could be taken from power generated by the genset.
In that case net power will be less than specified on
the identification plate
VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency. The W-SQ20 can be
connected for different voltages in single phase or tri
phase. The nameplate indicates the connection as
made in the factory; BE AWARE THAT THE
CONNECTIONS COULD BE RECONNECTED BY
FORMER USERS
FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 50 Hz correlates with
1500 rpm.
CURRENT. This shows the maximum current that is
acceptable at the specified frequency, voltage and
power factor. When connected in tri phase the
indicated current is the current between two phases
that can be taken off three times.
WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and
external installation equipment
CE-marking: the “CE” symbol shows that the
generating set is build according to European
Community safety regulations. This includes the
regulations regarding 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.
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
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.
2.1.3
DANGER
Warning signs draw 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.
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral (N) and all phase lines (L1, L2
and L3). Of course this is the case when using
a Mastervolt Mass Systemswitch.
Electrical safety
This warning sign indicates parts which could
be live. The voltage of 230V or 230V/400V
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.
Realise that people are not used to have
230V/400V available on a vehicle. Put
warning signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
•
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.
EN / W-SQ20 for mobile applications / April 2010
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.
Circumstances could make it also necessary to take
additional measures. Be aware of wet conditions and
hazardous environments caused by explosive gases etc
2.1.2
Using the auto-start/stop (interval) mode the
generator can start unexpectedly. When
working on the electrical system, the 3 Amp
fuse must be removed from the control panel
and the battery plus cable must be removed
from the battery.
2.1.4
Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas. 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.
Do not use the generator set when the vehicle
is inside a building or in other enclosed area’s.
Be aware using the generator in wind still
conditions, when the exhaust fumes could
accumulate under, around or even in the
vehicle.
7
INFORMATION
2.1.5
Operation
External moving parts like fans and V-belts are covered by
the soundshield and therefore the W-SQ20 is very safe
when the soundshield is closed.
•
Keep a fire extinguisher on hand.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
BREAK
THROUGH
HERE
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 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. 3: 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 3.
•
Poor electrical connections or using wiring which
is not suited for the rated currents can cause
overheating and possibly fire.
Fire and explosion
2.1.7
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
8
•
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.
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.
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
2.3
•
2.2
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
skin. If signs of decomposition are evident, or if in
doubt, always wear disposable heavy duty
gloves.
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.
EN / W-SQ20 for mobile applications / April 2010
2.3.1
THE W-SQ20
Features
This generating set includes a 4 cylinder diesel engine
which is connected by close coupling to a tri phase
synchronous alternator in a sound attenuated capsule.
The set is mounted on a steel base frame and mounted
securely on anti vibration mounting pads to the capsule
base. The complete set is again on rubber mountings. All
cables and hoses are guided through the capsule’s sides.
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 are:
•
This users manual (number: 40200616)
•
An installation manual (number: 40200626)
•
A users manual for DCC (number: 40200261).
•
A quick reference guide for DDC (number
50200275)
Not included in the standard delivery but available as
options are:
•
Parts manual; number: 40200187
•
Workshop manual; number: 40200174
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.
All manuals are available
www.whisperpower.eu.
on
our
web
site
9
INFORMATION
2.4
2.4.1
COMPONENTS
Main components to identify
01
02
03
04
05
06
07
08
09
10
11
12
Thermostat housing
Boiler connection
Engine coolant pump
V-belt
Exhaust connection
Engine coolant OUT
Battery +
Battery Fuel out
Fuel in
Engine coolant IN
Rubber engine mounting
15
16
17
18
Filler cap engine oil
Filler cap engine coolant
Rubber engine mounting
Rocker cover
Fig. 4: Left View main components W-SQ20
Fig. 5 Top View main components W-SQ20
10
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Hoist eye rear
Engine speed adjusting
screw
Fuel injector
Glowplug (4x)
Fuel filter
Fuses
Control panel
Air cleaner element
Indentification plate
Oil sump handpump
Coolant drain plug
Engine oil dipstick
Fuel solenoid
Oil filter
Injection pump air bleeding
screw
Fuel lift pump for manual
priming
Fuel injection pump
Fig. 6 Front View main components W-SQ20.
37
38
39
40
41
42
43
44
45
46
48
49
50
51
52
53
Temperature switch
Hoist eye front
Alternator
Exhaust manifold
(watercooled)
Hoist eye alternator
Digital Diesel Control (DDC)
Expansion tank
Power take off hydro pump
Remote control
AC power output
Coolant injection bend
Engine oil pressure switch
Starter motor solenoid
Starter motor
Engine serial number (above
starter motor solenoid)
Automatic voltage regulator
(AVR)
Fig. 7: Rear View main components W-SQ20.
EN / W-SQ20 for mobile applications / April 2010
11
INFORMATION
2.4.2
Generator control panel
2.5
2.5.1
Start / Stop
Internal fuel pump Digital Diesel Control
Fuse 3A
Fuse 3A
Remove fuse
before maintenance
Auxiliary
Fuse 10A
External Fuel Pump
Fuse 3A
Whisper Digital Diesel Operation Unit
Observe instructions in the manual
Replace fuses with same type and rating
Fig: 8 Control panel.
Fig. 9 Digital Diesel Control unit
2.4.3
Remote control panel
03
02
01
04
05
06
TECHNICAL INFORMATION
AC alternator
The tri phase synchronous alternator is directly coupled,
one bearing, brushless, rotating field design, 12 wire, four
pole (1500 RPM) and regulated by an Automatic Voltage
Regulator (AVR).
The exciter stator has a residual magnetism, which
guarantees self-exciting of the generator on start-up (that
thereby generates a residual voltage of about 10%
nominal voltage).
The AVR, powered by an auxiliary circuit on the main
stator, acts on the exciter stator indirectly controlling the
field generated by the main rotor by means of the
sequence exciter rotor - diode bridge - main rotor.
The voltage regulator controls and keeps constant the
average voltage of one phase. The voltage setting on the
AVR can be adjusted with the help of a trimmer “V”
between 185 and 290 Volts. (See par. 5.3.1)
A frequency control progressively deactivates the machine
when the drive motor speed drops below a pre-set,
adjustable threshold preventing over-excitement at low
operating speeds and abating the load engage effects on
the engine.
The AVR works only within limits of the set frequency 50
Hz. When operating below the lower limit of 46 Hz ± 1 Hz
the AVR will stop regulating to avoid overloading the
exciter coil (This setting can be changed with trimmer
“UF”). (See par. 5.3.1)
When applying the generator set at 60 Hz the AVR is readjustable as well. To operate at 60 Hz the engine RPM
and Digital Diesel Control settings must also be changed.
For the USA market a dedicated manual (Art. No
50200444) is available for 60 Hz applications. Please refer
to the Whisper Power centre for specific instructions to
convert the generating set to 60 Hz.
A further option is to readjust the stability of the regulator.
In the event of very irregular (alternating) loads it could be
necessary to change this setting with the help of trimmer
“S” to avoid interference of the regulator and the
alternating load. In conclusion the regulator reaction time
can be modulated to eliminate any voltage instability that
may arise. (See par.5.3.1)
07
01
Generator load indicator
02
Failure LED
03
Start button
04
Stop button
05
Display
06
Select button
07
Set button
Fig. 10: Digital Diesel remote control panel
Fig. 11 Automatic Voltage Regulator (AVR).
12
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
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 option. 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 (see figure 7)
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.
Fig. 12 AVR Trimmers (potentiometers).
2.5.5
Alarms and shut down
The power comes from 12 wires that can be connected in
star, delta or combined double / star and double / delta
arrangements to take off different voltages. For tri phase
400V use, the alternator should be connected in star. For
single voltage 230V use the wires should be connected in
double delta. The alternator is specially designed that in
this way one can take off the full power off the generator.
However the use of three groups of 230 V taken from the
three corners of a single delta arrangement is
recommended. Other voltages (115 Volt) can be arranged
as well. Further technical data on the connections of the
alternator can be found in drawings and diagrams in this
manual.
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 two functions
guarded: oil pressure and coolant temperature.
All alarm switches are closed when no malfunction occurs.
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.
2.5.2
2.5.7
Engine
The W-SQ20 generating set is based on the Mitsubishi
S4S 4 cylinder 4 stroke diesel engine. The engine is
indirectly injected. The engine is water cooled and the
cooling liquid is cooled by a radiator.
The engine has been specially adapted for the Whisper
Power application and is very different from the standard
engine supplied for industrial applications!
EN / W-SQ20 for mobile applications / April 2010
2.5.6
Monitoring
Refer to the operating of the Digital Diesel Control
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.
13
INFORMATION
2.5.8
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
Oil viscosity:
We recommend a multigrade oil 15W40.
3
Oil capacity:
Excluding the oil filter the content of the crankcase is
9 l. Including the oil filter it is 9.3 l.
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance
4
2.5.9
Hour counter
The remote control offers several timer functions that
helps to schedule maintenance.
Oil pressure
•
Minimum at idle 98 kPa (1 kgf/cm²/14psi) (1 bar).
•
At 2230 rpm ±300 kPa (3 kgf/cm²/45 psi) (3 bar).
2.5.13 Cooling liquid
2.5.10 Load indicator
On the remote control the load will be indicated on the
display and by the LED-bar. The load is measured by
current transformers on the alternator. All phases are
monitored and overload of all phases or just one or two
phases will provoke an alarm or even shut down when the
alarm is ignored.
2.5.11 Fuel specification
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.
2.5.12 Oil information
1
Specification:
The oil must be suitable for oil changes as specified in
the maintenance chapter. The Mitsubishi 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 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.
14
The engine is cooled by cooling liquid. The capacity of this
system depends on the size of the radiator piping and
other parts in the cooling system
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. Initially one
can fill the engine via the filling cap on the exhaust
manifold. Fill up till the level is just below the filling cap.
Additional filling of engine cooling system has to be done
via the expansion tank. 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. On the tank is an overflow
connection. This connection can be used to connect an
open hose to drain the overflow of the cooling liquid to
outside the vehicle.
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.
The cooling liquid in the engine is pressurised. A high
pressure hose connects the manifold to the expansion
tank.
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
2.5.14 Technical data
GENERAL
Model
RPM
Alternator
Engine
Number of cylinders
Displacement
Bore X stroke
Combustion air consumption
Continuous power engine
Cooling system
Fuel lift pump engine
Starting battery (optional)
Fuel consumption
Control
ELECTRICAL SPECIFICATIONS
Output voltage
Output rating
Voltage tolerance
Frequency tolerance
Alternator
Voltage regulation:
MECHANICAL SPECIFICATIONS
Supply includes
Dimensions in sound shield hxwxd
Dimensions without sound shield
Colour
Weight with sound shield
Weight without sound shield
Max. installation angle
Standard supplies
Available as option:
EN / W-SQ20 for mobile applications / April 2010
W-SQ20
1500
3 phase synchronous (air cooled)
Mitsubishi diesel, model S4S (Japan)
4
3331 cm3
94x120 mm
10 m³/min.
24 kW mechanical power
By means of a radiator.
Mechanical pump, additional electrical pump available upon request
110 Ah 12V
2-9 litre/hour, load dependent
Digital Diesel Control including automatic start/stop
230/400V 50 Hz alternating current (AC) tri phase re-connectable to take off single
phase or dual voltage
Whisper 20 kVA at powerfactor cos phi = 0.8up to 1
± 2% (balanced load)
± 3%
Air cooled, brushless, four pole, twelve wire, synchronous
AVR
Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator
set without sound shield is optional)
126x68x80 cm
115x60x75 cm
Metallic silver / grey
580 kg
480 kg
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, spare part kits, PTO to
drive hydraulic pump
15
INFORMATION
Optional control for two speeds fans.
See chapter 4.8
2.5.15 Electrical diagram control wiring W-SQ20
Fig. 13 Electrical Diagram control wiring W-SQ20 for mobile applications
16
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
2.5.16 Terminal modes 115VAC – 230VAC - 400VAC 50Hz
Fig. 14 Terminal modes W-SQ20
EN / W-SQ20 for mobile applications / April 2010
17
INFORMATION
2.5.17 Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR
* TO CONNECT NEUTRAL TO GROUND
REFER TO 2.1.3 USER MANUAL W-SQ20
*
Fig 15. Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR
18
April 2010 / W-SQ20 for mobile applications / EN
INFORMATION
2.5.18 AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)
TOCONNECT
CONNECT
NEUTRAL
GROUND
** TO
NEUTRAL
TOTO
GROUND
REFERTO
TO
2.1.3
USER
MANUAL
W-SQ2025U
REFER
2.1.3
USER
MANUAL
WHISPER
Fig 16. AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)
EN / W-SQ20 for mobile applications / April 2010
19
INFORMATION
2.5.19 Electrical diagrams radiator fan control
Fig. 17: Electrical diagram for standard fan control
using a 230V AC radiator fan
JUNCTION BOX AIR FANS
TRAFO
230/115VAC
200VA
12VDC
K1
K2
230VAC
DIMENTION BOX: 270x270x180 MM
Fig. 18: Electrical diagram fan control using a 230V
AC radiator fan – with two speeds fans (optional)
20
April 2010 / W-SQ20 for mobile applications / EN
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
2
Maximum oil level
Minimum oil level
1
2
Fig. 19:
3.2
3.2.1
In operation checks:
1 Check for abnormal noise or vibration
2 Check the voltage
3 Power
source
selector
switch
(off/external
power/generator power). Switch to power source
generator. If a Mass System switch is installed, this
operates automatically.
4 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 Switch to an other AC power source, if available. If a
Mass Systemswitch is installed, this is done
automatically.
3.2.2
OPERATING INSTRUCTIONS
Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 19).
2 Check cooling system (coolant level).
3 Power
source
selector
switch
(off/external
power/generator power). Switch to power source
switch "OFF", or switch off all consumers in the usual
way. If a Mass Systemswitch 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.
EN / W-SQ20 for mobile applications / April 2010
Extended operating instructions
Check when starting the first time or after a longer period
of rest:
1
2
3
4
5
6
If there is any damage caused by transport or
installation.
Check if the installation conforms to the installation
instructions.
Ensure the generating set is free to turn without
obstruction.
Check all hoses and hose connections for leaks.
Check all cables and cable end terminal connections.
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.
21
OPERATION
2
3
4
5
Check coolant in the expansion tank.
Check for leakages.
If no Mass Systemswitch 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 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).
70% or the rated generating set’s maximum load. Please
note this when switching on your electrical devices!
Nevertheless, the W-SQ20 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
A restart protection prevents starting the engine when it is
already running, which could cause damage.
Stopping the generating set:
Checks once the generator is in operation:
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
coolant 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
Switch to an other 230V/400V power source, if
available. If a Mass System switch is installed, this is
done automatically.
1
2
3
Check for abnormal noise or vibration.
Check the voltage.
Power
source
selector
switch
(off/external
power/generator power). Switch to power source
generator. If a Mass System switch 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).
If the engine is not running and ‘failure’ and
‘charging’ LED is blinking, reset by stop
button, otherwise it will drain the start battery
In order to prolong the generating set’s life expectancy, the
nominal electrical demand on the system should be about
22
April 2010 / W-SQ20 for mobile applications / EN
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 (see section
5.3.5, Meggering).
The alternator bearing is greased for life and is therefore
not regreasable
4.2
4.2.1
4.2.2
1
2
3
4
5
6
Bleeding fuel lines
Ensure there is sufficient fuel in the fueltank.
Loosen the air bleeding screw (1) 1,5 turns . See Fig
20.
Unlock lift pump plunger (2) (See fig 20) by turning it
to the left.
Operate the lift pump by hand moving the lift pump
plunger up and down, till fuel flows out free of air
bubbles.
Lock lift pump plunger (2) (See fig 16) by pushing it
full down and turning it to the right.
Tighten the air bleeding screw (1)
ENGINE
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.
Fig. 20: Bleeding fuel lines
1 = Air bleeding screw
2 = Liftpump plunger
4.2.3
Valve clearance
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).
EN / W-SQ20 for mobile applications / April 2010
23
MAINTENANCE
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.
A clogged filter results in a lack of output of the generating
set.
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. 23
01
4.2.6
01
Fuel filter
Fig. 21 Location fuel filter cartridge
4.2.5
Tensioning V-belt
The alternator bracket allows for readjust of the V-belt.
Deflections should be 13 mm (see fig. 24)
Replacing oil filter
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. 24 Tension V-belt.
4.2.7
01
Air cleaner element
The interval for cleaning of the air cleaner element (figure
25) strongly depends on environmental conditions. Check
the condition of the element at least every 500 running
hours, but should be at least every six months.
02
Fig. 25: Air cleaner element
01
Engine oil filter
02
Engine oil dipstick
Fig. 22 Location engine oil filter and dipstick.
24
April 2010 / W-SQ20 for mobile applications / EN
MAINTENANCE
4.3
REGULAR MAINTENANCE
AFTER FIRST 300 HOURS:
•
Retighten the cylinder head bolts and adjust the
valve clearance. (Refer to § 5.4.2).
CHECK DAILY:
•
Oil level (see fig. 26)
EVERY 300 HOURS:
•
Check the impeller of the engine coolant pump.
•
Replace the oil filter.
•
Replace the fuel filter
Replacement depends or the condition of the
fuel. We recommend replacement every 300
hours.
Take care the oil level is never
below the mark. Do not add oil
when the level is still above
the mark
1
2
Minimum oil level
Maximum oil level
Fig. 26:
1
2
CHECK DAILY:
•
Level cooling liquid
•
Hoses for loose connections or deterioration.
AFTER FIRST 50 HOURS:
•
Change oil and replace the oil filter.
Have the engine run until it is on temperature and
stop it. Replace the oil filter. Drain oil by the sump
pump into a suitable retainer and fill up with fresh
oil. Start the engine again and have it run for 5
minutes. Stop the engine again and pause 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 and readjust V-belt.
•
Check the electrical connections.
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.
EVERY 500 HOURS:
•
Check air cleaner element.
EVERY 1000 HOURS:
•
Replace the V-belt.
•
Retighten the cylinder head bolts and adjust the
valve clearance. (Refer to § 5.4.2).
•
Check and clean the radiators
EVERY 2000 HOURS:
•
Replace or clean the air cleaner element.
•
Check lubricating oil pressure
•
Clean and check or replace fuel injector nozzles
and check injection pressure.
When the generator set runs less than 100
hours a year the oil should be changed yearly
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
EN / W-SQ20 for mobile applications / April 2010
25
MAINTENANCE
4.3.1
Maintenance schedule
4.3.2
Check oil level
daily
Check the level of the cooling liquid
daily
Hoses for loose connections or deterioration
daily
Change oil and oil filter
after first 50 hours
Check and tighten nuts, bolts, etc.
after first 50 hours
Check exhaust
after first 50 hours
Check and readjust V-belt
after first 50 hours
Check electrical connections
after first 50 hours
Change oil
150 hours
Check battery
150 hours
Check and readjust V-belt
150 hours
Retighten cylinderhead bolts and
readjust valve clearance
Check impeller engine coolant pump
after first 300 hours
300 hours
Replace oil filter
300 hours
Replace fuel filter
300 hours
Check the air cleaner element
500 hours
Replace the V-belt
1000 hours
Retighten cylinderhead bolts and readjust
valve clearance
Check and clean radiators
1000 hours
Check lubricating oil pressure
1000 hours
2000 hours
Check injector and injection pressure
2000 hours
Replace or clean the air cleaner element
2000 hours
26
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.
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.
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
5 TROUBLE SHOOTING
5.1
ALTERNATOR/ ELECTRICAL FAULTS
Beware of parts which are live!
Remove 3 Amp. Fuse in the control panel
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
5.1.1
General
If any problem should occur, check basic conditions and
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.
These measurements should only be carried out by an
experienced electrician
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
AC-ALTERN. TEMP
WATER TEMP
OIL PRESSURE
AC VOLTAGE
HIGH CURRENT
FREQUENCY
5.1.2
If during these measurements the engine immediately
stops after starting and an error code is displayed at the
remote control panel ( “AC VOLTAGE”), one can start the
generator by means of a “service start” at the service
menu (see paragraph “service start” of the user’s manual
of the Digital Diesel Control). By doing this, the generator
will keep running for 2 minutes before it stops. This offers
you the possibility to carry out measurements to
investigate the cause of the failure.
Check if the engine is running correctly at 1500 RPM (50
Hz) according to its settings and does as well under load.
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.
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.
Problem
Communication error between the panel end the generator
Starter battery voltage too low
No output battery charging voltage
AC-alternator 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
Trouble shooting table alternator
PROBLEM
No output (Voltage) at all
CAUSE
• Circuit breaker "off" or faulty main fuse
• Faulty fuse of the AVR
• Loss of residual magnetism.
• Low engine RPM.
• Faulty RPM.
• Rotor diode broken.
Generator output voltage too
low when no load is on it (less
• Engine is not reaching the rated RPM.
EN / W-SQ20 for mobile applications / April 2010
SOLUTION
Check switches and fuses and measure
directly on the alternator to exclude external
causes.
Check fuse of the AVR
Check the residual magnetism, temporally
increase RPM with 15%. Try to and flash the
alternator (see special procedures)
Check the engine RPM and adjust (refer to
special procedures).
Check by independent excitation if the problem
is in the AVR or in the windings and replace if
necessary (see special procedures).
Check the diode in the rotor (see special
procedures). The W-SQ20 has one diode
block/rectifier unit.
See special procedures to readjust RPM.
27
TROUBLE SHOOTING
PROBLEM
than 225V between phase and
neutral).
CAUSE
• Faulty AVR. When slightly too low,
adjustment could be necessary
• Defective diode
SOLUTION
Try to readjust AVR. Check by independent
excitation if the problem is in the AVR or in the
windings and replace AVR if necessary (see
special procedures).
Check the diode in the rotor (see special
procedures). The W-SQ20 has one diode
block/rectifier unit.
• When
applying
3
phase:
an
unbalanced load; check the voltage of
the other phases. When the voltages
are different this is caused by an
unbalanced load.
• Engine is not reaching the rated RPM.
Possibly too much load or engine
problems (lack of fuel)
• Faulty AVR or readjustment necessary
Bring load in balance. When slightly out of
balance, remove the sense wires to the phase
with the highest load and check if the voltage
on the other phases is not too high.
Generator output voltage too
high, (more than 235V)
• Over-energising due to defective AVR
or wrong AVR setting
Check AVR, readjust and replace if necessary
capacitor specification and replace AVR if
necessary (see special procedures)..
Generator output voltage too
high, (more than 235V)
In no load condition it is OK
• Unbalanced load
Bring load in balance.
When slightly out of balance, remove the
sense wires to the phase with the highest load
and check if the voltage on the other phases is
not too low.
Generator voltage fluctuates.
• Disturbances on the electrical system/
user side.
• AVR reacts on fluctuating load
Check if electrical load is fluctuating
Generator output voltage too
low under load (less than 225V).
In no load condition it is OK
Generator is not able to start an
electric motor
5.2
• Engine runs irregularly.
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
As the alternator is very much underrated the problem will appear by the
engine RPM collapsing
Check the electric motor’s current draw
required for starting. This should not exceed
the rated generator output current. This could
be remedied by using a "soft-start". Inquire at
your nearest Whisper Power dealer or directly
at the manufacturer, Whisper Power in the
Netherlands.
ENGINE FAULTS
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).
28
Try to readjust the voltage
Check by independent excitation if the problem
is in the AVR or in the windings and replace
AVR if necessary (see special procedures).
Readjust the stability setting on the AVR
trimmer “ST”
When engine runs irregularly see section:
"Engine runs irregularly" at the “Engine faults”
paragraph.
Remove 3 Amp. fuse in the control panel
while working on the generator to prevent the
engine from starting.
5.2.1
Switch off a load; (part off) consumers
See to engine RPM problems
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.
A failure code is displayed when a hardware failure at the
generator is detected.
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
AC-ALTERN. TEMP
WATER TEMP
OIL PRESSURE
AC VOLTAGE
HIGH CURRENT
FREQUENCY
5.2.2
Problem
Communication error between the panel end the generator
Starter battery voltage too low
No output battery charging voltage
AC-alternator temperature is to high (generators for mobile applications only)
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
Trouble shooting table engine
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 indicate “LOW
START BAT”
The problem must be an electric malfunction.
No reaction at all
• Starter battery switched "OFF".
Check position of the battery switch and switch
"ON".
Replace fuse
• Faulty fuse on the control panel
No reaction or clicking noises,
or slow cranking
• Starter battery voltage insufficient
(battery too weak).
• Too thick engine lubricating oil.
• Wiring control system faulty
• Starter motor faulty
Starter is turning engine
smoothly, but engine fails to
start
• 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
Engine runs irregularly.
• Unsuitable contaminated fuel
• Lack of fuel.
EN / W-SQ20 for mobile applications / April 2010
Check battery voltage. Recharge the battery.
Inspect battery terminals and cables for a good
electrical connection (inspect against corrosion,
tattered wires, etc.)
Change oil for a lower viscosity.
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
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.
29
TROUBLE SHOOTING
PROBLEM
CAUSE
• Choked fuel filter.
• Disturbances on the electrical system/
user side.
• Faulty fuel lift pump.
• Choked air cleaner element.
• Lack of air.
• Choked exhaust system, exhaust
blocked,.
• Air in the fuel pipes
SOLUTION
Check fuel filter and fuel lift pump: clean or
replace if necessary.
Check if electrical load is fluctuating
Try the pump by manual operation. Repair when
faulty or replace
Check the air intake
Check the exhaust piping; inspect manifold inside
Bleed air from fuel system (refer to maintenance
section).
Have the injector tested and cleaned if necessary.
• Blocked injector.
Adjust valve clearance.
• Wrong valve clearance.
• Temporarily hunting (this will disappear when engine has run in).
Engine speed drops
•
•
•
•
Drain oil to proper level
Check fuel supply system: fuel pump and filter.
Check air intake.
Check the exhaust piping; inspect manifold inside
• Defective generator (windings,
bearings or other)
• Damaged engine
Reduce the electrical load (switch off some
consumers).
Generator must be sent to manufacturer for repair
of damaged bearing or winding.
Repair by Whisper Power service
Too much oil.
Lack of fuel.
Lack of intake air.
Choked exhaust system, exhaust
blocked.
• Generator overloaded
Engine does not stop on
command
• Fuel solenoid is not switching off •
• Loss of control
Faulty Digital Diesel Control unit. Stop the engine
manually by the stop handle.
Check wire connections to stop solenoid. Check
solenoid valve function. Replace if necessary
Engine exhaust smokes
• Faint blue smoke - generally the result
of light load
• 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
cleaner element., inlet temperature too
high, unsuitable fuel or water in fuel.
Increase load.
Engine starts, but stops after 10
up to 30 seconds
• Protection system stops the engine;
this can be caused by oil pressure
failure, lack of cooling water. Overload,
loose wire or faulty alarm switch.
Digital Diesel Control will help to
indicate failure.
Refer to paragraph 2.5.5. and 3.2.2 for
information on the alarm system. Bypassing the
switches can help to confirm the failure.
Engine stops by itself
• Overload or short circuit.
• Lack of fuel.
Switch off the consumers and test for short circuit.
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.
• Oil pressure low. (oil pressure switch
tripped).
30
Check the oil level.
Check the compression.
Check the fuel .
Check for overload.
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
PROBLEM
CAUSE
• Excessive heat in cooling system
(thermo-switch tripped).
• Lack of cooling water (exhaust switch
tripped).
• Impeller broken.
• Cooling water 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.
• Thermostat faulty
Sooty, black exhaust.
• Generator is being overloaded. Digital
Diesel Control will indicate “HIGH
CURRENT”.
• Insufficient intake air.
• Choked air cleaner element.
• Fuel injector faulty.
• Valve clearance incorrect.
• Poor fuel quality.
• Poor quality lubricating oil.
• Continuous running with very low load.
SOLUTION
Check cooling liquid level in expansion tank;
check coolant flow, coolant pump,.
Check if radiator fans work properly and switch to
higher speed. Air piping system might block
circulation. Almost all problems of overheating are
caused by faulty installation: bents in the routing
of cooling pipes that capture air bubbles (air
locks) or hot air circulating bacj into the radiators.
Refer to installation manual.
Check and clean
Repair by Whisper Power service.
Readjust or replace V-belt
Check thermostat and replace
Check electrical load and switch off some
consumers
Check intake air paths and filter, clean and
replace if necessary.
Replace injector.
Readjust valve clearance
Use better quality diesel.
Use better quality oil.
Increase load up to 70% of nominal power and
have the engine run for a few hours
Loss of power
● Wrong measurement. Check if the load is measured correctly. Does the Amp meter show
the correct value? When calculating the load by multiplying voltage and amps this should be
done by using the exact values, taking into account the power factor of the consumers. When
any doubt, measure the power directly with an appropriate instrument.
Bring the oil to the correct level
• Overfull oil sump.
Replace the fuel filter.
• Choked fuel filter.
Check air inlet openings; clean air cleaner
• Choked air cleaner element.
element..
Check the exhaust system.
• Exhaust blocked.
Check and replace if nescessary
• Faulty fuel pump
Have the injector checked.
• Injector blocked.
Have the compression measured.
• Loss of compression, sticking or
damaged piston ring.
Clean or replace the rings.
Have the compression measured and have the
• Wear out of cylinder.
engine overhauled.
Over-temperature
• Overload.
• Low level of coolant or air in the
cooling system
•
•
•
•
5.2.3
Radiator choked by dirt
Hot air circulation in radiator.
Broken or slipping V-belt.
Faulty thermostat
Warnings
Take away the overload.
Fill up with coolant and release air bubbles.
Check if there are air blocks in the system; refer
to the installation manual
Check the cooling system thoroughly.
Clean radiator
Replace and adjust the V-belt tension.
Check the thermostat or replace.
● Unusual noise comes from generating set.
● Exhaust gases suddenly colour dark.
● Engine failure warning light is on
Generator must be shut off immediately if:
● Motor RPM suddenly rises or drops.
EN / W-SQ20 for mobile applications / April 2010
31
TROUBLE SHOOTING
5.2.4
Service address
If you cannot correct a problem with the aid of the malfunction table, contact your Whisper Power Service Centre
or Whisper Power Netherlands for an extended service
list, tel: INT +31-512-571550.
32
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
5.3
5.3.1
SPECIAL PROCEDURES ALTERNATOR
Automatic Voltage Regulator (AVR)
The voltage regulator has a ±2% voltage precision in the
machine working range with distortion free loads.
The phase voltage can be adjusted by trimmer “V” (see
figure 27) from 185 to 290V.
The regulator is equipped with a frequency dependant
excitation limiter; the frequency can be calibrated by
trimmer “UF”, which is factory set at 46Hz (56Hz), ±1Hz.
On reaching this frequency, the machine begins to reduce
its voltage until it deactivates for very low frequencies.
A fuse protects the regulator and generator against
overloads and/or faults; a pocket has been provided on the
edge of the board to hold a spare fuse (rapid type 32x6.3
2A).
Another trimmer “ST” allows to adapt the regulator to the
generator parameters.
The regulator has been built to suppress the voltage
surges on releasing the load that are below 20% at
nominal load.
AVR SETTINGS
To select the AVR settings access the control board after
removing the cover. Most adjustments are factory set to
ensure satisfactory results in the operating tests on
commissioning. Further adjustments may be necessary to
ensure optimum operation under specific working
conditions.
If the alternator has to operate at 50Hz the jumper “J”
across the terminals marked “60Hz” has to be left in place,
if it has to operate at 60Hz this jumper should be removed.
The output voltage can be changed by adjusting
potentiometer “V”. Take the generating set to its nominal
speed and turn until the required voltage is obtained. If a
small variation in speed causes a change in voltage, then
the bottom speed protection should first be calibrated. The
voltage reference (orange wires) should be connected:
•
to terminals “0” and “115” for an output voltage
between 100 and 140V (factory setting)
•
to terminals “0” and “230” for an output voltage
between 200 and 280V.
EN / W-SQ20 for mobile applications / April 2010
Fig. 27. Automatic Voltage Regulator (AVR)
To increase the range of available voltages by about 15%
use terminal “Pa” instead of terminal “0”. Caution: if the
voltage is set any higher than its maximum limit the
generator may be damaged.
Setting the bottom speed at 50 (60)Hz: start up rotation of
the generating set adjusting it to obtain a frequency of 46
(56)Hz. Turn trimmer “UF” until the voltage begins to
drop. Restore nominal speed.
Caution: if the bottom speed is set at too low a frequency
the generator may be damaged. On the other hand, too
high a frequency can cause voltage drops with high loads.
If on load voltage fluctuations are experienced adjust
potentiometer “ST”, which modulates the reaction time of
the regulator to external inputs, thereby eliminating any
instability in the alternator-load system.
5.3.2
Residual voltage check / excitation
procedure (flashing)
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 exciting the exciter field
coil directly, disconnecting the AVR first. Put 12 Volt
directly over the electronic regulator terminals taking
polarity into account.
33
TROUBLE SHOOTING
Fig.28 Residual voltage check / excitation procedure.
When using the starter battery fuse it and limit the current
with a 30 Ohm resistor. Flashing can be done while the
engine is running and the wiring is connected. When a
variac (variable power supply) is available one should be
able to control the voltage manually.
CAUTION
If the starter set battery is used for exciting
one must take care. A short circuit can cause
heavy sparking, fire and injuries.
When external excitation does not bring back voltage, the
rotating rectifier diodes should be tested and a winding
resistant test should be executed.
5.3.3
5.3.4
Winding resistant values
If after establishing and correcting any fault on the AVR
and diodes, and output is still low when separately excited,
then the main rotor, stator auxiliary and exciter stator
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:
Testing rotary rectifier diodes
The diodes in the rotor can be checked with a multimeter.
The diodes are integrated in a rectifier unit. When all
diodes are faulty the alternator will not generate any
voltage. When one or more diodes are faulty the alternator
will produce too low voltage.
The flexible leads connected to the diodes 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
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. In case of faulty diodes replace the
rectifier unit. One can get access to the diode unit by
taking off the backend of the alternator.
34
Fig. 29. Location rectifier diode block
Resistance W-SQ20
•
•
•
•
•
Resistance main stator windings
Resistance rotor windings
Resistance auxiliary winding
Resistance exciter stator winding
Resistance exciter rotor winding
5.3.5
0.33 Ohm
1.18 Ohm
3.85 Ohm
18 Ohm
0.18 Ohm
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. The
AVR 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 2 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
(60-80ºC) from a fan heater or similar apparatus into the
generator air inlets or outlets.
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
5.4
5.4.1
SPECIAL PROCEDURES ENGINE
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.
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:
5.4.2
Adjusting valve clearance and
retightening the cylinder head bolts.
Both procedures have to be executed with a cold engine.
When both procedures are executed be sure to retighten
the cylinder head bolts before adjusting the valve
clearance. When retightening the cylinder head bolts,
drain the coolant by removing the coolant drain plug (ref.
to fig. 4).
Loosen the bolts slightly, remove the rocker assembly (the
rocker arms, shaft, and stays) and then retighten the bolts
to the specified torque in the numerical order illustrated
(ref. to fig. 31).
Tightening torque cylinder head bolt:
Rocker stay tightening torque:
01
118 ± 5 Nm
10-20 Nm
Fig. 31. Cilinderhead bolt tension sequence.
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 “O” on the crankshaft pulley with
the mark on the gear case
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.
01
Engine speed adjusting screw
Fig. 30 Location engine speed adjustment screw.
It is very important to identify the correct setting assembly
(see fig. 30). The screw is to be locked in position with the
lock-nut.
Fig. 32. Checking valve clearance (turning)
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
EN / W-SQ20 for mobile applications / April 2010
35
TROUBLE SHOOTING
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 1-3-4-2
Turn the crankshaft 180º 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 4 and finally to 2.
5.4.3
Disassembling instructions
It could be necessary for repair or checks to disassemble
the generating set.
Following instructions will help:
1
The design of the W-SQ20 makes it possible to do
most repairs on the spot. The connections of the
alternator are very accessible. The same is true for
the diode of the rotor
2
The sound shield canopy can be disassembled
according to exploded view below (figure 33)
Fig. 33 Exploded view soundshield
36
April 2010 / W-SQ20 for mobile applications / EN
TROUBLE SHOOTING
3
4
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
Taking the generator set from its mounting, or to
replace a mounting can be done according to the
drawing below (figure 34)
5
One can take off the complete alternator housing.
Before the alternator can be taken off all cables and
wiring has to be taken loose first.
6
Reassembling the generating set one should take
care of alignment, cleaning the surfaces between
engine and alternator and tighten the bolts crosswise
and gradually.
7
Use Loctite 577 to seal the fittings, which should first
be cleaned and made free of oil and grease.
8
Test the generating set first outside its capsule and
check very carefully for leakages before putting it
back in its enclosure.
Fig. 34 Exploded view rubber mountings
EN / W-SQ20 for mobile applications / April 2010
37
SPARE PARTS LIST
6 SPARE PARTS LIST
A complete parts manual in English is available as an option number: number: 40200187 (***)
A work shop manual in English is available as an option number: 40200174 (***).
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 (*)+(**)
article no. 40201560
article no. 40201561
ARTICLE NO
DESCRIPTION
50206122
Fuel filter (*)
50208120
V-belt (*)
40208121
Oil filter (*)
50230007
Air cleaner element (*)
50209145
Measuring coil Wh 20/25, 3 pcs (***)
50208010
Rotary diode three phase (**)
50208015
Alternator bearing including O-ring (**)
50208020
Voltage regulator
50209104
Local control panel
50209099
Digital Diesel Control Unit 3 phase (***)
50212170
Fuses 10 Amps(*)
50212154
Fuses 3 Amps (*)
50212197
Fuses 32 x 6.3 / 2 Amps (*)
50201559
Wiring loom complete (***)
50209102
Digital Diesel Remote control panel
130010915
Cable remote control 15 mtr, including connectors
50208033
Overhaul gasket kit / Seal kit (***)
50208030
Cylinder head gasket kit
50206040
Glow plug, 4pcs (**)
50208050
Nozzle injector, 4pcs (**)
50206045
Thermostat (**)
50206038
Gasket thermostat (**)
50208034
Gasket rocker cover (**)
More extensive parts list on the internet: WHISPERPOWER.EU (fast moving parts)
38
April 2010 / W-SQ20 for mobile applications / EN
MAINTENANCE LOG
MAINTENANCE LOG
first service after 50 hours:
hour counter:
next service (every 150 hours)
hour counter:
EN / W-SQ20 for mobile applications / April 2010
remarks
39
Kelvinlaan 82, 9207 JB Drachten, The Netherlands
Tel : + 31-512-571550 / Fax : + 31-512-571599
www.whisperpower.eu / info@whisperpower.nl