USERS MANUAL M-SC6 / 8 / 10 - 3000 RPM - Marine diesel generating set 230V / 50Hz Digital Diesel Control Art.nr. 40200351 WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel.: +31-512-571550 Fax.: +31-512-571599 www.whisperpower.eu V1.
CONTENTS CONTENTS: 1 INTRODUCTION .............................................................................................................................................................. 4 1.1 General .............................................................................................................................................................. 4 1.2 Service and maintenance ..................................................................................................................
CONTENTS 4 MAINTENANCE ............................................................................................................................................................. 23 4.1 Alternator .......................................................................................................................................................... 23 4.2 Engine ..............................................................................................................................................
INTRODUCTION 1 INTRODUCTION 1.1 GENERAL 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. The M-SC6/8/10 Marine 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: 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.
INTRODUCTION 1.5 identification plate are also some basic features of the set: 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.
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.
INFORMATION 2.1.5 Operation 2.1.6 External moving parts like fans and V-belts are covered by the canopy and therefore the Whispers are very safe when the canopy is closed. 8 Fuels can be flammable. Proper handling limits the risk of fire and explosion. Nevertheless take note of the signs on the generating set which show symbols in a triangle indicating danger. • Avoid refilling the fuel tank while the engine is running. When oil or fuel is leaking do not use the generating set.
INFORMATION 2.2 TRANSPORT, LIFTING AND STORAGE When lifting the generating set avoid any risk of personal injuries, do not stand un-der the generating set.. • Use soft slings to avoid damage • On the engine are two lifting eyes, only to be used to take the generator out of the capsule. Do not use to lift the set including the capsule and certainly not including the steel foundation plate ! • After transporting the generating set check for damage before installation.
INFORMATION 2.4 2.4.
INFORMATION 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Cooling water injection bend Temperature switch exhaust Heat exchanger Starter motor solenoid Starter motor Rubber engine mounting Fuel in Ø8mm Battery negative (–) Battery positive (+) Fuel out Ø8mm Raw water inlet V-belt Engine coolant pump Exhaust manifold (watercooled) Figure 4: Rear view main components M-SC6, 8 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Temperature switch Thermostat housing Filler cap engine oil Filler cap engine coolant Rocker
INFORMATION 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Cooling water injection bend Temperature switch exhaust Heat exchanger Starter motor solenoid Starter motor Rubber engine mounting Fuel in Ø8mm Battery negative (–) Battery positive (+) Fuel out Ø8mm Raw water inlet V-belt Engine coolant pump Exhaust manifold (watercooled) Fig.
INFORMATION 2.4.2 Generator control panel 2.5 Start / Stop Internal fuel pump Digital Diesel Control Fuse 3A Fuse 3A Remove fuse before maintenance Auxiliary Fuse 10A External Fuel Pump Fuse 3A Whisper Digital Diesel Operation Unit Observe instructions in the manual Replace fuses with same type and rating Fig. 8: Control panel 2.5.1 6 5 1 2 4 3 Fig. 10: Digital Diesel Remote Control panel 2.4.
INFORMATION 2.5.4 The oil must be suitable for oil changes as specified in the maintenance chapter. The engine must be run on heavy duty lubricating oil meeting the requirements of API class CD, CF or CF_4. Battery charger On the engine is an alternator generating 40 Amp 12V. This current is rectified to charge the battery. The voltage is regulated at ±14.4V. 2.5.5 2.5.6 It is very important to use the correct oil specification.
INFORMATION 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.
INFORMATION 2.5.14 Wiring codes and colours number battery > starter motor starter motor > DDC starter motor > LCP battery > ground ground > LCP ground (GND) DDC > glow plug DDC > starter solenoid LCP > fuel lift pump + LCP > fuel lift pump – DDC > LCD DDC > oil pressure switch LCP > oil pressure switch DDC > oil temperature switch LCP > oil temperature switch DDC > exhaust temperature switch LCP > exhaust temperature switch DDC > fuel solenoid (hold) DDC > fuel solenoid (pull) DDC > fuel solenoid (com.
INFORMATION 2.5.15 Lay out control wiring Fig.
INFORMATION 2.5.
INFORMATION 2.6 DIAGRAM ELECTRONIC GOVERNOR The M-SC8 and 10 3000 rpm are equipped with an electronic governor in addition to the mechanical governor that is on other Whisper models. A governor keeps the speed (RPM=Rotations Per Minute) of the engine at a fixed value. The RPM of the engine correlates with the frequency of the electrical output (3000 RPM =50 Hz) of the alternator. Under full load the RPM of the Whisper models that has only a mechanical governor can drop 75 RPM (=2.
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, filling the starter battery with acid, connecting the battery to earth and connecting the digital remote control panel.
OPERATION 3.2.2 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 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.
OPERATION 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.
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. 19) Take care the oil level is never below the mark. Do not oil when the level is still above the mark 1 2 Minimum oil level Maximum oil level Fig. 19: CHECK DAILY: • Level cooling liquid • Hoses for loose connections or deterioration. • Water inlet filter.
MAINTENANCE 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. 4.3.1 EVERY 300 HOURS: • Replace the impeller of the raw water pump.
MAINTENANCE 4.3.2 anti-freeze from a can until the pump, heat exchanger and manifold are filled. Putting out of service When not using the generating set for a longer period it is recommended to execute an engine preservation procedure. 5 The coolant can stay in the engine 1 Clean the engine. 6 Disconnect the battery and store it in a place free of frost and dry and charge it regularly. 2 Loosen the fuel suction pipe and fuel return and put them in a can with preservation diesel fuel.
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 menu (see paragraph “service start” of the user’s manual of the Digital Diesel Control). By doing this, the generator will keep running for 2 minutes before it stops. This offers you the possibility to carry out measurements to investigate the cause of the failure.
TROUBLE SHOOTING PROBLEM than 210V/105V)). CAUSE • Defective capacitor. • Defective diode (one of the two) Generator output voltage too low under load (less than 210V/105V). In no load condition it is ok • Generator is overloaded. • Engine is not reaching the rated RPM. • Defective capacitor • Defective voltage regulator (Optional for M-SC8/10) Generator voltage too high, (more than 245V/130V) • Engine is running too fast (RPM too high).
TROUBLE SHOOTING 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 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.
TROUBLE SHOOTING PROBLEM CAUSE • To thick engine lubricating oil. SOLUTION Change oil for a lower viscosity. 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. Fill up with fuel or replace with better quality. • 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.
TROUBLE SHOOTING PROBLEM Engine exhaust smokes CAUSE • 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. SOLUTION Increase load.
TROUBLE SHOOTING PROBLEM CAUSE • Wear out of cylinder. SOLUTION Have the compression measured and have the engine overhauled. Over-temperature • Overload. • Low level of cooling oil or air in the cooling system Take away the overload. Fill up with liquid and release air bubbles. Check if there are air blocks in the system; refer to the installation manual Check the cooling system thoroughly. • • • • • • 5.2.3 Water inlet system blocked. Broken impeller. Water strainer choked Heat exchanger choked.
TROUBLE SHOOTING 5.3 SPECIAL PROCEDURES ALTERNATOR 5.3.1 Residual voltage check / excitation procedure 5.3.2 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter. When the diode is faulty the alternator will not generate any voltage. 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 suffered a short circuit.
TROUBLE SHOOTING 5.3.3 Winding resistant values 5.4 If after establishing and correcting any fault on the capacitor and diodes 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.
TROUBLE SHOOTING 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).
TROUBLE SHOOTING 5.4.3 Measuring exhaust backpressure The exhaust system must be of adequate size -1 5/8”/ 40 mm - and maximal length (refer to installation manual). When any doubt; backpressure has to be measured. An easy way to measure for back-pressure is to use a water column. A water column can be made visible in a plastic tube along a yardstick and fitting the end to a hose connection to fit in the adaptor on the injection bent after removing the exhaust temperature switch. 5.4.
TROUBLE SHOOTING Figure 26: exploded view sound shield M-SC6, 8 and 10 EN / M-SC6/8/10 / December 2010 37
SPARE PARTS LIST 6 SPARE PARTS LIST A parts manual in English is available as an option number: number: 40200381 (***)(M-SC6 and 8); A work shop manual in English is available as an option number: 40200171. We recommend the following spares for service and maintenance.
SPARE PARTS LIST Fig.
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks: next service (every 150 hours): hour counter: remarks: 40 December 2010 / M-SC6/8/10 / EN
NOTES NOTES EN / M-SC6/8/10 / December 2010 41
NOTES NOTES 42 December 2010 / M-SC6/8/10 / EN
NOTES NOTES EN / M-SC6/8/10 / December 2010 43
Kelvinlaan 82, 9207 JB Drachten, Netherlands Tel: + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / info@whisperpower.
