USERS MANUAL FOR MOBILE APPLICATIONS W-SC6 / SC10 - 3000 RPM - Mobile diesel generating set 230V / 50Hz Electronic Whisper Control Art.nr. 40261111 WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten The Netherlands Tel.: +31-512-571550 Fax.: +31-512-571599 www.whisperpower.
CONTENTS CONTENTS: 1 INTRODUCTION .............................................................................................................................................................. 4 1.1 General .............................................................................................................................................................. 4 1.2 Service and maintenance ..................................................................................................................
CONTENTS 3 OPERATION .................................................................................................................................................................. 23 3.1 General ............................................................................................................................................................ 23 3.2 Operating Instructions ............................................................................................................................
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-SC6 / SC10 -3000RPM mobile diesel generating set is manufactured and marketed by WhisperPower. It is important to read this manual before installing and operating the generating set.
INTRODUCTION 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-locks” blocking the circulation of the liquid. Other examples of installation problems are hot air circulation into the radiator and the radiator fan sucking exhaust gasses into the radiators.
INTRODUCTION 1.5.2 Identification plate 2 All required identification data are on the identification plate. For location of the identification plate see figure 1: 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.
INFORMATION 2 INFORMATION 2.1 SAFETY 2.1.3 Earth insulation failures 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. According to local regulations and depending on the application it could be necessary to take measures for protection against earth insulation failures.
INFORMATION 2.1.5 Operation External moving parts like fans and V-belts are covered by the soundshield and therefore the W-SC6 / SC10 is very safe when the soundshield is closed. BREAK THROUGH HERE 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.
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.
INFORMATION 2.4 2.4.1 COMPONENTS Main components to identify 01 02 03 04 05 06 07 Fuel injection pump Fuel injector W-SC6: 2x W-SC10: 3x Glow plug W-SC6: 2x W-SC10: 3x Alternator (12VDC) Engine oil dipstick Coolant drain plug Oil sump hand pump Fig.
INFORMATION 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 Dry exhaust Temperature switch alternator Starter motor solenoid Starter motor Rubber engine mounting Coolant generator out Coolant engine in Coolant engine out Battery negative (–) Fuel in Ø8mm Fuel out Ø8mm Battery positive (+) Coolant generator in V-belt Engine coolant pump Exhaust manifold (watercooled) Fig.
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: 7 Control panel. 2.4.
INFORMATION 2.5.5 Alarms and shut down In the event of malfunctioning this will be indicated by the failure light, details will be shown on the display and the engine will be shut down. There are three functions guarded: oil pressure, coolant temperature and alternator temperature. Too high alternator temperature indicates the alternator coolant to be blocked or the pump impeller to be damaged. All alarm switches are closed when no malfunction occurs. A contact is cut in the event of an alarm.
INFORMATION 2.5.12 Cooling liquid Both the engine and alternator are cooled by cooling liquid. The capacity of both systems depend 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.
INFORMATION 2.5.
INFORMATION Optional control for two speeds fans. See chapter 2.5.17 ALTERNATOR TEMP. SWITCH 2.5.
ALTERNATOR TEMP.
ALTERNATOR TEMP.
INFORMATION 2.5.16 Electrical diagrams 230 V AC / 50 Hz Fig.
INFORMATION 2.5.17 Electrical diagrams radiator fan control Fig. 14: Electrical diagram for standard fan control using 230V AC radiator fans Fig.
INFORMATION Fig.
INFORMATION 2.5.18 Diagram electronic governor (standard) In addition to the mechanical governor, the W-SC6 and SC10 are standard equipped with an electronic governor. A governor keeps the speed (RPM=Rotations Per Minute) of the engine at a fixed value. The RPM of the engine correlates with the frequency of the electrical output (3000 RPM =50 Hz) of the alternator. Under full load the RPM of the Whisper models that have only a mechanical governor can drop 75 RPM (=2.
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 Power source selector switch (off/external power/generator power). Switch to power source generator.
OPERATION 2 3 4 5 Check coolant in both expansion tanks. 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, the fuel lift pump starts pumping and the starting procedure will begin (by pushing the Stop button the system is deactivated).
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.
MAINTENANCE A smeer of oil has to be put on the seal of the filter before fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further. 4.3 REGULAR MAINTENANCE CHECK DAILY: Oil level (see fig. 24) Take care the oil level is never below the mark. Do not add oil when the level is still above the mark 1 2 Fig. 21 Minimum oil level Maximum oil level Fig. 24: 4.2.
MAINTENANCE EVERY 300 HOURS: Check the impeller of the alternator coolant pump. 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 500 HOURS: Check the air strainer element Replace the impeller of the alternator coolant pump. When replacing the impeller the gasket between the pump case and the cover should be replaced as well.
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.
TROUBLE SHOOTING PROBLEM Generator output voltage too low under load (less than 210V/105V). In no load condition it is ok CAUSE Generator is overloaded. Engine is not reaching the rated RPM. Defective capacitor SOLUTION Switch off a load; (part off) consumers. Refer to engine RPM problems Check capacitor and replace if necessary (refer to special procedures). Generator voltage too high, (more than 245V/130V) Engine is running too fast (RPM too high).
TROUBLE SHOOTING 5.2.2 Trouble shooting table engine PROBLEM Diesel engine fails to crank, the starter makes clicking noises, or the engine cranks very slowly CAUSE SOLUTION Almost certainly this is an electrical problem. Display will indicate “LOW START BAT” 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.
TROUBLE SHOOTING PROBLEM Engine speed drops CAUSE Faulty electronic governor Too much oil. Lack of fuel. Lack of intake air. Choked exhaust system, exhaust blocked. Generator overloaded Generator over energised. Defective generator (windings, bearings or other) Damaged engine SOLUTION Replace faulty parts. Contact WhisperPower service department for advice Drain oil to proper level Check fuel supply system: fuel pump and filter. Check air intake.
TROUBLE SHOOTING PROBLEM CAUSE 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.
TROUBLE SHOOTING 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. a low resistance in the forward direction.
TROUBLE SHOOTING 5.4 5.4.1 SPECIAL PROCEDURES ENGINE Setting the RPM RPM is set by the manufacturer and should not need readjustment! When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor. If readjustment of the RPM is necessary, please contact your WhisperPower Service Centre for advice. 5.4.2 The clearance of both (intake and exhaust) valves should be 0.25 mm in cold condition.
TROUBLE SHOOTING 5.4.3 Disassembling instructions 4 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. 5 The rotor can be taken off by removing the bold which goes through the shaft (normal clockwise threaded). The end of the shaft is specially threaded to push off the rotor from the conic stub shaft, which is on the flywheel, using a 6-mm rod of 165mm length (W-SC6) or 185mm length (W-SC10) and a M10 bolt.
SPARE PARTS LIST 6 SPARE PARTS LIST A complete parts manual in English is available as an option number: number: 40200182 (***) A work shop manual in English is available as an option number: 40200171 (***). 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. 40201860 article no.
SPARE PARTS LIST Fig 31: Water pump type M EN / W-SC6/10 for mobile applications / March 2011 37
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: next service (every 150 hours) hour counter: 38 remarks March 2011 / W-SC6/10 for mobile applications / EN
NOTES NOTES EN / W-SC6/10 for mobile applications / March 2011 39
Kelvinlaan 82, 9207 JB Drachten, The Netherlands Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / info@whisperpower.
