M-SQ 16 User`s manual

M-SQ 16 User`s manual
USER’S MANUAL
M-SQ16
- 1500 RPM -
Marine diesel generating set 230-50 Hz
Digital Diesel Control
Art.nr. 40200291
WHISPERPOWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: +31-512-571550
Fax: +31-512-571599
www.whisperpower.com
V1.1 June 2016
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-SQ16 ....................................................................................................................................................... 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 ..................................................................................................................... 12
2.5.6
Control ............................................................................................................................................. 13
2.5.7
Remote control ................................................................................................................................ 13
2.5.8
Hour counter .................................................................................................................................... 13
2.5.9
Load indicator .................................................................................................................................. 13
2.5.10
Fuel specification ............................................................................................................................. 13
2.5.11
Oil information ................................................................................................................................. 13
2.5.12
Cooling liquid ................................................................................................................................... 13
Technical data .................................................................................................................................................. 14
2.5.13
Wiring codes and colours ................................................................................................................ 15
2.5.14
Lay out control wiring....................................................................................................................... 16
2.5.15
Electrical diagram 230 V AC / 50 Hz ............................................................................................... 17
3
OPERATION .................................................................................................................................................................. 18
3.1
General ............................................................................................................................................................ 18
3.2
Operating Instructions ...................................................................................................................................... 18
3.2.1
Summarised operating instructions (daily use) ................................................................................ 18
3.2.2
Extended operating instructions ...................................................................................................... 18
2
June 2016 / M-SQ16 / EN
CONTENTS
4
MAINTENANCE ............................................................................................................................................................. 21
4.1
Alternator .......................................................................................................................................................... 21
4.2
Engine .............................................................................................................................................................. 21
4.2.1
Preliminary instructions ................................................................................................................... 21
4.2.2
Bleeding fuel lines ........................................................................................................................... 21
4.2.3
Valve clearance ............................................................................................................................... 21
4.2.4
Replacing fuel filter .......................................................................................................................... 22
4.2.5
Replacing oil filter ............................................................................................................................ 22
4.2.6
Readjustment of V-belt .................................................................................................................... 22
4.3
Regular maintenance ....................................................................................................................................... 23
4.3.1
Maintenance schedule..................................................................................................................... 24
4.3.2
Putting out of service ....................................................................................................................... 24
5
TROUBLESHOOTING ................................................................................................................................................... 25
5.1
Alternator/ electrical faults ................................................................................................................................ 25
5.1.1
General............................................................................................................................................ 25
5.1.2
Troubleshooting table ...................................................................................................................... 25
5.2
Engine faults..................................................................................................................................................... 26
5.2.1
General............................................................................................................................................ 26
5.2.2
Troubleshooting table ...................................................................................................................... 27
5.2.3
Warnings ......................................................................................................................................... 29
5.2.4
Service address ............................................................................................................................... 29
5.3
Special procedures alternator........................................................................................................................... 30
5.3.1
Residual voltage check / excitation procedure ................................................................................ 30
5.3.2
Testing rotary rectifier diodes .......................................................................................................... 30
5.3.3
Winding resistant values .................................................................................................................. 30
5.3.4
Meggering ....................................................................................................................................... 30
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................................................. 31
5.4.3
Measuring exhaust backpressure .................................................................................................... 32
5.4.4
Disassembling instructions .............................................................................................................. 33
6
SPARE PARTS LIST ..................................................................................................................................................... 34
MAINTENANCE LOG ............................................................................................................................................................... 36
EN / M-SQ16 / June 2016
3
INTRODUCTION
1 INTRODUCTION
1.1
GENERAL
The M-SQ16 Marine Diesel Generating set is
manufactured and marketed by WhisperPower.
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 WhisperPower M-SQ16 generating set.
This manual is valid for the following models:
Part
number
41108005
Description
M-SQ16 230V 1500rpm
41108006 M-SQ16 230V 1500rpm -ungrounded
For other models see other manuals available on our
website: www.whisperpower.com.
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.
1.2
SERVICE AND MAINTENANCE
Regular service and maintenance should be carried out
according to the directions in this manual. For service and
4
maintenance one can appeal to the manufacturer or the
dealers.
1.3
GUARANTEE
WhisperPower 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.
This generating set’s correct operation 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.
June 2016 / M-SQ16 / EN
INTRODUCTION
Example 4: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.
WhisperPower cannot be held responsible for damage
caused by the unattended running generator.
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. WhisperPower does not accept
liability for damage due to use of the generator, possible
errors in the manuals and the results thereof.
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.
Automatic start/stop
WhisperPower cannot be held responsible for damage
caused by the unattended running generator using the
auto-start/stop mode or interval mode.
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 spare parts only!
1.4
LIABILITY
WhisperPower does not accept responsibility for damage,
injuries or casualties which are the result of operation of
EN / M-SQ16 / June 2016
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.
1.5.2
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.
Identification plate
All required identification data are on the identification
plate. For location of the identification plate see figure 1.
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
Fig. 1: Location identification plate
1
6
The identity of the generating set is given by the
SERIAL NUMBER.
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.
June 2016 / M-SQ16 / 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.
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
Electrical safety
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.
2.1.3
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 Lloyd’s 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 WhisperSwitch.
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.
2.1.4

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.
EN / M-SQ16 / June 2016
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.
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-SQ16 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.
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.

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.
2.1.7

2.1.6
Fire and explosion

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
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.
Keep a fire extinguisher on hand.
Chemicals
June 2016 / M-SQ16 / EN
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.

2.3
THE M-SQ16
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 user’s manual).
2.3.2
Remote control
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 full automatic remote control panel including 15 mtr
cable comes as standard with the Whisper generating set.

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)
Included in the delivery is:

This user’s manual (number: 40200291)

An installation manual (number: 40200231)

A user’s manual for DCC (number: 40200261).

A quick reference guide for DDC (number
40200275)

While the battery is stored it should be recharged
every 12 weeks.
2.3.3
Documentation
Not included in the standard delivery but available as
options are:

Parts manual; number: 40200184

Workshop manual; number: 40200173
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


EN / M-SQ16 / June 2016
Accessories included in the standard
delivery
Expansion tank, hose and fittings
Special hose connector for measuring exhaust
back pressure (refer to paragraph 5.4.3)
9
INFORMATION
2.4
2.4.1
COMPONENTS
Main components to identify
01
02
03
04
05
06
07
08
Hoist eye rear
Hoist eye front
Thermostat housing
Exhaust manifold (watercooled)
Temperature switch
exhaust
Cooling water injection
bend
Heat exchanger
Rubber engine mounting
Fig. 3: Rear view main components M-SQ16
09
10
11
12
14
14A
Filler cap engine oil
Rocker cover
Filler cap engine coolant
Temperature switch
coolant
Engine oil pressure
switch
Engine serial number
Fig. 4: Rear view main components M-SQ16
10
June 2016 / M-SQ16 / EN
INFORMATION
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Fig. 5: Front view main components M-SQ16
31
32
33
34
35
36
37
38
39
40
41.
42
43
44
45
46
47
48
49
Fuel filter
Identification plate
Air cleaner element
Fuses
Control panel
Digital Diesel Control
(DDC)
Expansion tank Ø8mm
Bypass cooling water out
Ø25.4mm
Bypass cooling water in
Ø25.4mm
Exhaust hose Ø51mm
Power take off (PTO)
Engine air intake
Remote control
AC power output
Engine oil filter
Oil sump hand pump
(optional)
Failsafe
Battery negative (–)
35mm²
Fuel out Ø8mm
Fuel in Ø8mm
Battery positive (+)
35mm²
Raw water inlet Ø25.4mm
Raw water pump
V-belt
Engine coolant pump
Alternator (12VDC)
Glow plug (4x)
Fuel injector (4x)
Fuel solenoid
Engine Oil Dipstick
Fuel bleeding screw
Starter motor solenoid
Starter motor
Fuel lift pump for manual
priming
Fuel injection pump
Fig. 6: Front view main components M-SQ16
EN / M-SQ16 / June 2016
11
INFORMATION
2.4.2
Generator control panel
2.5
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 feedback
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.
Fig. 7: Control panel
2.5.2
Fig. 8: Digital Diesel Control unit
2.4.3
TECHNICAL INFORMATION
Remote control panel
5
6
1
2
The M-SQ16 generating set is based on the Mitsubishi
S4Q2 4 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
WhisperPower application and is very different from the
standard engine supplied for industrial applications!
2.5.3
7
4
3
Fig. 11: Digital diesel remote control panel
1. Start button
5. Failure lamp
2. Stop button
6. Generator load indicator
3. Select button
7. Display
4. Set button
Engine
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 user’s 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.
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
12
June 2016 / M-SQ16 / EN
INFORMATION
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
Hour counter
The remote control offers several timer functions that help
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.
2.5.10 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.
2.5.11 Oil information
1
Oil viscosity:
We recommend a multigrade oil 10W40.
3
Oil capacity:
Excluding the oil filter the content of the crankcase is
7 l. Including the oil filter it is 8 l. Note that the engine
may contain some residual oil due to testing at the
factory.
While filling, check the lubricating oil level by means
of the engine oil dipstick. Do not overfill with
lubricating oil as this may have a detrimental effect on
engine performance.
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
2
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
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.
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 CF, CF-4, CH-4, CI-4 or
CI-4 plus.
EN / M-SQ16 / June 2016
4
Oil pressure

Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar).

Normal at 1500 rpm ±196 to 392 kPa (2-4 kgf/cm²
- 28 to 57 psi) (2-4 bar).
2.5.12 Cooling liquid
Always use coolant which is compatible with
aluminium components of the cooling system.
Do not mix coolants with different kinds of
chemical compound, as this may cause
congelation of the coolant. In case of doubt
refresh the content of the entire cooling
system. Use only long-life type G12+ cooling
liquid in order to minimize maintenance.
The engine is cooled by cooling liquid. The capacity of this
system of the M-SQ16 is 7.6 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 antifreeze 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
13
INFORMATION
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.
Technical data
GENERAL
Model
RPM
M-SQ16
1500
Alternator
Engine
water-cooled, synchronous
Mitsubishi diesel, model S4Q2 (Japan)
Number of cylinders
Displacement
4
2505 cm³
Bore X stroke
Combustion air consumption
80x103 mm
2.5 m³/min.
Continuous power engine
Cooling system
16 kW
indirect cooling by raw water, 20-25 l/min.
Cooling water pump
Fuel lift pump engine
PTO driven WhisperPower self-priming impeller pump, type M16
mechanical, additional electric pump (12 V DC) available upon request
Starting battery (optional)
Fuel consumption
110 Ah 12V
2-7 litre/hour, load dependent
Control
Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage
Output rating:
230V - 50 Hz alternating current (AC) single phase
16 kVA = 16kW at power factor cos phi = 1
Voltage tolerance
Frequency tolerance
± 5%
± 5%
Alternator
Voltage regulation:
brushless, four pole, synchronous
Capacitor (+ optional AVR)
MECHANICAL SPECIFICATIONS
Supply includes
Sound shield with steel base, mounted on rubber anti-vibration mounts.
(Generator set without sound shield is optional)
Dimensions hxwxd
Colour
116.0 x 68.0 x 70.0 cm
Metallic silver / grey
Weight
Max. installation angle
454 kg including sound shield
25 degrees
Standard supplies
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
Optional:
14
June 2016 / M-SQ16 / EN
INFORMATION
2.5.13 Wiring codes and colours
number
colour
red
cross section
35 mm²
starter motor > DDC
starter motor > LCP
1
13
red
red
6 mm²
2,5 mm²
battery > ground
ground > LCP ground (GND)
2
black
black
35 mm²
4 mm²
DDC > glow plug
DDC > starter solenoid
3
4
brown
yellow
4 mm²
2,5 mm²
DDC > LCD
DDC > oil pressure switch
5
6
grey
purple
1,5 mm²
1 mm²
LCP > oil pressure switch
DDC > water temperature switch
6
7
purple/black
blue
1 mm²
1 mm²
LCP > water temperature switch
DDC > exhaust temperature switch
7
8
blue/black
blue/green
1 mm²
1 mm²
LCP > exhaust temperature switch
DDC > fuel solenoid (hold)
8
9
blue/pink
green
1 mm²
1,5 mm²
DDC > fuel solenoid (pull)
DDC > fuel solenoid (com.)
20
17
pink
black
2,5 mm²
2,5 mm²
B+ terminal alternator > starter motor
DDC >R terminal alternator
21
18
red
white
6 mm²
1,5 mm²
DDC > L terminal alternator
DDC > current measuring transformer
19
11
orange
black
1,5 mm²
1 mm²
DDC > current measuring transformer
DDC > LCP
11
12
red
black
1 mm²
1,5 mm²
DDC > LCP
DDC > LCP
14
16
red
red/green
1,5 mm²
1,5 mm²
DDC > generator AC output
DDC > generator AC output
33
33
brown
blue
1 mm²
1 mm²
battery > starter motor
DDC=Digital Diesel Control Unit
LCP=Local Control Panel
EN / M-SQ16 / June 2016
15
INFORMATION
2.5.14 Lay out control wiring
Fig 10: Electrical diagram control wiring M-SQ16
16
June 2016 / M-SQ16 / EN
INFORMATION
2.5.15 Electrical diagram 230 V AC / 50 Hz
Fig. 11: Electrical diagram 230V
EN / M-SQ16 / June 2016
17
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
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 WhisperSwitch 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 another AC power source, if available. If a
WhisperSwitch is installed, this is done automatically.
Fig. 12
3.2.2
3.2
3.2.1
OPERATING INSTRUCTIONS
Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 12).
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 WhisperSwitch 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.
18
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.
June 2016 / M-SQ16 / EN
OPERATION
2
3
4
5
6
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.
Regularly check the siphon vent in the cooling water
supply.
If no WhisperSwitch 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.
EN / M-SQ16 / June 2016
4
Be aware that especially in harbours the
coolant water inlet can easily be blocked by
floating objects.
Power
source
selector
switch
(off/shore
power/generator power). Switch to power source
generator. If a WhisperSwitch 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-SQ16 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
19
OPERATION
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 another 230V power source, if available. If a
WhisperSwitch 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.
20
June 2016 / M-SQ16 / 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.
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
4.2.1
4.2.2
1
2
3
4
5
6
Bleeding fuel lines
Ensure there is sufficient fuel in the fuel tank.
Loosen the air bleeding screw (1) 1,5 turns . See Fig
16.
Unlock lift pump plunger (2) (See fig 13) 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 13) 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. 13: Bleeding fuel lines
1 = Air bleeding screw
2 = Lift pump 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 / M-SQ16 / June 2016
21
MAINTENANCE
4.2.4
Replacing fuel filter
4.2.6
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
Readjustment of V-belt
The alternator bracket allows for readjust of the V-belt.
Deflections should be 10 mm (refer to fig. 16).
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. 16
Fig. 14
1 = Oil filter
A smear 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. 15
22
June 2016 / M-SQ16 / EN
MAINTENANCE
4.3
REGULAR MAINTENANCE
CHECK DAILY:

Oil level (see fig. 17)
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. 17
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.
EN / M-SQ16 / June 2016
EVERY 150 HOURS:

Change oil.

Check the battery acid level (not applicable when
WhisperPower 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.
EVERY 300 HOURS:

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.
EVERY 1000 HOURS:

Replace the V-belt.

Retighten cylinder head bolts/adjust + valve
clearance.
EVERY 2000 HOURS:

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
23
MAINTENANCE
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
4.3.1
Maintenance schedule
Check oil level
daily
Check water inlet filter
daily
Check the level of the cooling liquid
daily
Change oil and oil filter
after first 50 hours
Check and tighten nuts, bolts, etc.
after first 50 hours
Check exhaust
after first 50 hours
Check air vent
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 air vent
150 hours
Check and readjust V-belt
150 hours
Check impeller water pump
150 hours
Replace impeller water pump
300 hours
Retighten cylinder head bolts and readjust
valve clearance
Replace oil filter
300 hours
Replace fuel filter
300 hours
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
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.
300 hours
Retighten cylinder head bolts , adjust valve
clearance
Replace the V-belt
1000 hours
1000 hours
Check lubricating oil pressure
2000 hours
Check injector and injection pressure
2000 hours
Check inlet air filter
2000 hours
Check cooling system
2000 hours
24
4.3.2
June 2016 / M-SQ16 / EN
TROUBLESHOOTING
5 TROUBLESHOOTING
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
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
EXHAUST TEMP
WATER TEMP
OIL PRESSURE
AC VOLTAGE
HIGH CURRENT
FREQUENCY
5.1.2
breakers. Also check if measuring instruments give the
correct value. If in doubt, measure directly on the
alternator terminals with an independent instrument.
This should only be carried out by an experienced
electrician. 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
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
Troubleshooting table
PROBLEM
No output (Voltage) at all
CAUSE
 Circuit breaker "off" or faulty fuse
 Low engine RPM.
 Loss of residual magnetism.
 Capacitor loose or broken.
 Rotor diodes broken.
Generator output voltage too
low when no load is on it (less
than 210V).
 No load at all or very low load.
 Engine is not reaching the rated RPM.
 Defective capacitor(s).
 Defective diode
Generator output voltage too
low under load (less than 210V).
In no load condition it is ok
EN / M-SQ16 / June 2016
 Generator is overloaded.
 Engine is not reaching the rated RPM.
 Defective capacitor
SOLUTION
Check switches and fuses and measure
directly on the alternator to exclude external
causes.
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-SQ16 has one diode in
the rotor.
Switch on a load and check voltage.
Refer to special procedures to readjust RPM.
Check capacitor and replace if necessary
(refer to special procedures).
Check the diode in the rotor and replace (refer
to special procedures).
Switch off a load; (part off) consumers.
Refer to engine RPM problems
Check capacitor and replace if necessary
(refer to special procedures).
25
TROUBLESHOOTING
PROBLEM
Generator voltage too high,
(more than 245V)
CAUSE
 Engine is running too fast (RPM too
high).
 Over-energising due to defective
capacitors
 Presence of a strong capacitive load
(leading power factor)
SOLUTION
Check engine speed and adjust (refer to
special procedures).
Check capacitor specification and replace
capacitors if necessary.
Compensate for this capacity and seek for
experts advice (WHISPERPOWER customers
service)
Generator voltage fluctuates.
 Disturbances on the electrical system/
user side.
 Engine runs irregularly.
Check if electrical load is fluctuating
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 WhisperPower dealer
or directly at the manufacturer, WhisperPower
in the Netherlands.
Generator is not able to start an
electric motor
5.2
ENGINE FAULTS
Remove 3 Amp. fuse in the control panel
while working on the generator to prevent the
engine from starting.
5.2.1
General
Most electrical problems 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).
When the engine is not cranking well, starting problems
almost always originate from battery problems or poor
battery cable connections.
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
EXHAUST TEMP
WATER TEMP
OIL PRESSURE
AC VOLTAGE
HIGH CURRENT
FREQUENCY
26
When engine runs irregularly refer to section:
"Engine runs irregularly".
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.
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
June 2016 / M-SQ16 / EN
TROUBLESHOOTING
5.2.2
Troubleshooting table
PROBLEM
CAUSE
SOLUTION
Diesel engine fails to crank, the
starter makes clicking noises, or
the engine cranks very slowly
 Almost certainly this is an electrical
problem. Display will indicate “LOW
START BAT”
 One other possibility is that the engine
is locked by water in the cylinder or
there is other severe damage..
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.
 Starter battery switched "OFF".
 Starter battery voltage
(battery too weak).
insufficient
 Faulty fuse on the control panel
 Wiring control system faulty
 Starter broken
 To thick engine lubricating oil.
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.
 Choked fuel filter.
 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
EN / M-SQ16 / June 2016
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 bend 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 WhisperPower service department for
advice.
Have the injector tested and cleaned if necessary.
Repair by WhisperPower 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
Check and repair
Check the air intake
Check the exhaust hose
Bleed air from fuel system (refer to maintenance
section).
27
TROUBLESHOOTING
PROBLEM
CAUSE
SOLUTION
 Blocked injector.
Have the injector tested and cleaned if necessary.
Adjust valve clearance.
 Wrong valve clearance.
 Temporarily hunting (this will disappear when engine has run in).
Engine speed drops




Too much oil.
Lack of fuel.
Lack of intake air.
Choked exhaust system, exhaust
blocked, rubber exhaust hose kinked.
 Generator overloaded
 Generator over energised.
 Defective
generator
bearings or other)
 Damaged engine
(windings,
Drain oil to proper level
Check fuel supply system: fuel pump and filter.
Check air intake.
Check the exhaust system.
Reduce the electrical load (switch off some
consumers).
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.
Repair by WhisperPower service
Engine does not stop on
command
 Fuel solenoid is not switching off •
 Loss of control
Faulty Digital Diesel Control unit. Stop the engine
manually by the stop handle.
Check wire connections to stop solenoid. Check
solenoid valve function. Replace if necessary
Engine exhaust smokes
 Faint blue smoke - generally the result
of light load
 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.
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 (exhaust
temperature alarm). Overload, loose
wire or faulty alarm switch. Digital
Diesel Control will help to indicate
failure.
Refer to paragraph 2.5.5 and 3.2.2 for information
on the alarm system. Bypassing the switches can
help to confirm the failure.
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 WhisperPower.
Check cooling water system flow: water pump,
inlet water filter, coolant flow.
 Oil pressure low. (oil pressure switch
tripped).
 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.
 Thermostat faulty
Sooty, black exhaust.
28
 Generator is being overloaded. Digital
Diesel Control will indicate “HIGH
CURRENT”.
Check the oil level.
Check the compression.
Check the fuel .
Check for overload.
Repair by WhisperPower service.
Readjust or replace V-belt
Check thermostat and replace
Check electrical load and switch off some
consumers
June 2016 / M-SQ16 / EN
TROUBLESHOOTING
PROBLEM
CAUSE
 Insufficient intake air.
 Choked air filter.
 Fuel injector faulty.
 Valve clearance incorrect.
 Poor fuel quality.
 Poor quality lubricating oil.
 Continuous running with very low load.
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 filter.
 Choked air filter.
Check the exhaust system.
 Exhaust blocked.
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 cooling liquid or air in the
cooling system





Water inlet system blocked.
Broken impeller.
Water strainer choked
Heat exchanger choked.
Broken or slipping V-belt.
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.
EN / M-SQ16 / June 2016
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
Check the cooling system thoroughly.
Replace and adjust the V-belt tension.
 Faulty thermostat
5.2.3
SOLUTION
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 and have the engine run for a few
hours
Check the thermostat or replace.
5.2.4
Service address
If you cannot correct a problem with the aid of the
malfunction table, contact your WhisperPower Service
Centre or WhisperPower Netherlands, tel: INT+31-512571555.
www.whisperpower.com.
29
TROUBLESHOOTING
5.3
SPECIAL PROCEDURES ALTERNATOR
5.3.1
Residual voltage check / excitation
procedure
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.
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
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-SQ16
Resistance
 Resistance both main stator windings
in series
 Resistance both rotor windings
 Resistance exciter stator winding
Fig. 18.
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
5.3.4
50Hz-230v
0.18 Ohm
3.90 Ohm
0.42 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.
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.
Fig. 19
30
June 2016 / M-SQ16 / EN
TROUBLESHOOTING
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 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:
Long bolts
Short bolts
118 ± 5 Nm
15 ± 2 Nm
12 ± 1 Nm
Fig. 21 Tighten sequence cylinder head bolts
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.
Fig. 20
1 =Adjustment screw operational RPM
2 =Adjustment screw max. RPM
It is very important to identify the correct setting assembly
(refer to fig. 20). The screw is to be locked in position with
the lock-nut.
EN / M-SQ16 / June 2016
31
TROUBLESHOOTING
The T.D.C. of compression stroke can be found by
aligning the T.D.C. mark (-0-) on the crankshaft pulley with
the mark on the gear case (ref. to fig. 22).
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.
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 bend after removing the
exhaust temperature switch.
MAXIMUM
69cm
27INCHES
Fig. 22 Finding TDC
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 –
4 – 2. Turn the crankshaft 180 degrees clockwise from the
T.D.C of cylinder 1 to the T.D.C of cylinder 3. and turn the
crankshaft 180 degrees further clockwise to the TDC of
cylinder 4 and adjust the valves. And again 180 degrees to
adjust cylinder 2.
32
Fig 23: Measuring exhaust backpressure
The bend 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).
June 2016 / M-SQ16 / EN
TROUBLESHOOTING
5.4.4
Disassembling instructions
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.
It could be necessary to disassemble the generating set
for repair or checks. Following instructions will help:
1
2
3
The design of the M-SQ16 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.
The sound shield canopy can be disassembled
according to exploded view below (figure 24).
To take the generating set out of the canopy all hose
and cable connections have to be taken off. The set is
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 24: Exploded view sound shield M-SQ16
EN / M-SQ16 / June 2016
33
SPARE PARTS LIST
6 SPARE PARTS LIST
A complete parts manual in English is available as an option number: number: 40200184 (***)
A work shop manual in English is available as an option number: 40200173 (***).
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. 40201360
article no. 40201361
article no. 40201362
ARTICLE NO
DESCRIPTION
50206122
50205120
Fuel filter (*)
V-belt (*)
40203121
50201350
Oil filter (*)
Raw water pump complete WhisperPower type M16 (***) (refer to fig. 25)
50206254
40206255
Impeller (50206259) + gasket (50206260) (*)
Cover type M16 (**)
50209018
50206257
Bolts cover (**) (6 pcs.)
Pump repair kit A consisting of: Shaft (50206267), Bearings (2 pcs) (50206264), O-ring (50206263),
Seal (50206262), Shim (50206271) Ring (50206265) Cam (50206269), Screw (50206265); Washer
(50206274) Screws (6pcs 50209018) Cover (50206255)
Pump repair kit B (**) consisting of: Bearings (2 pcs) (50206264), O-ring (50206263), Seal
(50206262), Ring (50206265)
Heat exchanger complete with appendages (***)
50209010
50201323
50201322
Water hoses with clamps (**)
Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering)
50209132
50201890
Measuring coil (***)
Rotary diode (**)
50201482
50209140
Alternator bearing including O-ring (**)
Voltage regulator (optional)
50209104
50209100
Local control panel (***)
Digital Diesel Control Unit (***)
50212170
50212154
Fuses 10 Amps(*)
Fuses 3 Amps (*)
50201366
50209102
Wiring loom complete (***)
Digital Diesel Remote control panel (***)
130010915
50206033
Cable remote control 15 mtr, including connectors
Overhaul gasket kit / Seal kit (***)
50206030
50206040
Cylinder head gasket kit
Glow plug, 4pcs (**)
50203050
50206045
Nozzle injector, 4pcs (**)
Thermostat (**)
50206038
50206034
Gasket thermostat (**)
Gasket rocker cover (**)
More extensive parts list on the internet: whisperpower.com (fast moving parts)
34
June 2016 / M-SQ16 / EN
SPARE PARTS LIST
Figure 25: Raw water pump WhisperPower type M16
EN / M-SQ16 / June 2016
35
MAINTENANCE LOG
MAINTENANCE LOG
first service after 50 hours:
hour counter:
remarks:
next service (every 150 hours):
hour counter:
remarks:
36
June 2016 / M-SQ16 / EN
NOTES
NOTES
EN / M-SQ16 / June 2016
37
NOTES
NOTES
38
June 2016 / M-SQ16 / EN
NOTES
NOTES
EN / M-SQ16 / June 2016
39
Kelvinlaan 82, 9207 JB Drachten, Netherlands
Tel : + 31-512-571550 / Fax : + 31-512-571599
www.whisperpower.com / info@whisperpower.com
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