Whisper Power M-SQ Pro 27, User Manual

Page 1: ...L M SQ27 1500 RPM Marine diesel generating set 230 400V 50Hz Digital Diesel Control WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com V1 August 2020 ...

Page 2: ...ivery 9 2 4 Components 10 2 4 1 Main components 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 14 2 5 3 Digital Diesel Control system 14 2 5 4 Battery charger 14 2 5 5 Alarms and shut down 14 2 5 6 Monitoring 14 2 5 7 Control 14 2 5 8 Remote control 14 2 5 9 Hour counter 14 2 5 10 Load indicator 14 2 5 11 Fuel spec...

Page 3: ...ING 29 5 1 Alternator electrical faults 29 5 1 1 General 29 5 1 2 Troubleshooting table 29 5 2 Engine faults 30 5 2 1 General 30 5 2 2 Troubleshooting table 31 5 2 3 Warnings 35 5 2 4 Service address 35 5 3 Special procedures alternator 35 5 3 1 Automatic Voltage Regulator AVR 35 5 3 2 Residual voltage check excitation procedure flashing 36 5 3 3 Testing rotary rectifier diodes 36 5 3 4 Winding re...

Page 4: ...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 subje...

Page 5: ... 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 1 4 Liability WhisperPower does not accept responsibility for damage injuries or casu...

Page 6: ...he engine RPM 50 Hz correlates with 1500 rpm 5 CURRENT This shows the maximum current that is acceptable at the specified frequency voltage and power factor When connected in tri phase the indicated current is the current between two phases that can be taken off three times 6 WEIGHT shows the net dry weight approximately in kg This is without fuel oil packing and external installation equipment 7 ...

Page 7: ... 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 Recreati...

Page 8: ...sher on hand Poor electrical connections or using wiring which is not suited for the rated currents can cause overheating and possibly fire 2 1 7 Chemicals Fuels oils coolants and battery electrolyte can be hazardous to personnel if not treated properly Do not swallow or have skin contact with these liquids Do not wear clothing that has been contaminated by fuel or lubricating oil Gaskets may be m...

Page 9: ...erable 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 see Digital Diesel Control user manual 2 3 ...

Page 10: ...housing 02 Boiler connection 03 Engine coolant pump 04 V belt 05 Exhaust connection 06 Bypass cooling water out 07 Bypass cooling water in 08 Battery 09 Battery 10 Fuel out 11 Fuel in 12 Raw water inlet 13 Raw water pump 14 Rubber engine mounting 15 Filler cap engine oil 16 Filler cap engine coolant 17 Rubber engine mounting 18 Rocker cover ...

Page 11: ...id 32 Oil filter 33 Injection pump air bleeding screw 34 Fuel lift pump for manual priming 35 Fuel injection pump 36 Heat exchanger 37 Temperature switch 38 Hoist eye front 39 Alternator 40 Exhaust manifold water cooled 41 Hoist eye alternator 42 Digital Diesel Control DDC 43 Expansion tank 44 Power take off hydro pump 45 Remote control 46 AC power output 47 Temperature switch exhaust 48 Cooling w...

Page 12: ...ween 185 and 290 Volts See par 5 3 1 A frequency control progressively deactivates the machine when the drive motor speed drops below a pre set adjustable threshold preventing over excitement at low operating speeds and abating the load engage effects on the engine The AVR works only within limits of the set frequency 50 Hz When operating below the lower limit of 46 Hz 1 Hz the AVR will stop regul...

Page 13: ...an be found in drawings and diagrams in this manual The tri phase synchronous alternator is directly coupled one bearing brushless rotating field design 12 wire four pole 1500 RPM and regulated by an Automatic Voltage Regulator AVR 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 betwee...

Page 14: ...hes 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 Monitoring Refer to the operating of the Digital Diesel Control 2 5 7 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 ...

Page 15: ...to minimize maintenance 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 liq...

Page 16: ...S Output voltage 230 400V 50 Hz alternating current AC tri phase re connectable to take off single phase or dual voltage Output rating 50Hz 20kVA at power factor cos phi 1 Voltage tolerance 2 balanced load Frequency tolerance 3 Alternator Air cooled brushless four pole twelve wire synchronous Voltage regulation AVR MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on r...

Page 17: ...INFORMATION EN M SQ 27 August 2020 17 2 5 15 Electrical diagram control wiring M SQ27 Fig 13 Electrical diagram control wiring M SQ27 ...

Page 18: ...INFORMATION 2 5 16 Terminal modes 115VAC 230VAC 400VAC 50H Fig 14 Terminal modes ...

Page 19: ...INFORMATION EN M SQ 27 August 2020 19 2 5 17 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR Fig 15 Generator diagram 3 phase with AVR 230V 400V 50Hz with AVR ...

Page 20: ...INFORMATION 2 5 18 AC Wiring Diagram single phase with AVR 230V Hz Double Delta Fig 16 AC wiring diagram single phase with AVR 230V Hz Double Delta ...

Page 21: ...ngine oil dipstick markings 3 2 Operating Instructions 3 2 1 Summarised operating instructions daily use Routine pre start checks 1 Check oil level 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 is operating automatically 4 Switch on batt...

Page 22: ...get the valve of the water outlet in case of a water exhaust gas separator 3 Check the water strainer 4 Check for leakages 5 Regularly check the siphon vent in the cooling water supply 6 If no WhisperSwitch is used Switch main Power Source Selector switch to OFF or switch off all devices 7 Switch on the battery switch Starting the generator By pushing the start button briefly the electric system i...

Page 23: ... 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 Stop...

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Page 25: ...first 50 hours may lead to cylinder glazing and high oil consumption For the same reason it is of the greatest importance to use the right oil specification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel lines Ensure there is sufficient fuel The Whispers are self bleeding To check the well functioning release the bleed scr...

Page 26: ...ipstick Fig 20 Location engine oil filter and dipstick Fig 21 Location rubber packing ring 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 4 2 6 Tensioning V belt The alternator bracket allows for readjust of the V belt Deflections should be 13 mm see fig 22 Fig 22 ...

Page 27: ...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 ...

Page 28: ...heck lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours Check cooling system 2000 hours 4 3 2 Taking 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 preserv...

Page 29: ...ault finding paragraph Digital Diesel Control system will help to indicate failures and display causes CAUTION If the voltage is set any higher than its maximum limit the generator may be damaged If the bottom speed is set at too low a frequency the generator may be damaged On the other hand too high a frequency can cause voltage drops with high loads A failure code is displayed when a hardware fa...

Page 30: ...ndition it is OK Unbalanced load Bring load in balance When slightly out of balance remove the sense wires to the phase with the highest load and check if the voltage on the other phases is not too low Generator voltage fluctuates Disturbances on the electrical system user side Check if electrical load is fluctuating AVR reacts on fluctuating load Readjust the stability setting on the AVR trimmer ...

Page 31: ...e 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...

Page 32: ... Blocked injector Have the injector tested and cleaned if necessary Wrong valve clearance Adjust valve clearance Temporarily hunting this will disappear when engine has run in Engine speed drops Too much oil Drain oil to proper level Lack of fuel Check fuel supply system fuel pump and filter Lack of intake air Check air intake Choked exhaust system exhaust blocked rubber exhaust hose kinked Check ...

Page 33: ...Diesel Control will indicate overload Check electrical load and switch off some consumers Insufficient intake air Choked air cleaner Check intake air paths and filter clean and replace if necessary Fuel injector faulty Replace injector Valve clearance incorrect Readjust valve clearance Poor fuel quality Use better quality diesel Poor quality lubricating oil Use better quality oil Continuous runnin...

Page 34: ...TROUBLESHOOTING PROBLEM CAUSE SOLUTION Faulty thermostat Check the thermostat or replace ...

Page 35: ... adjustments are factory set to ensure satisfactory results in the operating tests on commissioning Further adjustments may be necessary to ensure optimum operation under specific working conditions If the alternator has to operate at 50Hz the jumper J across the terminals marked 60Hz has to be left in place if it has to operate at 60Hz this jumper should be removed The output voltage can be chang...

Page 36: ...iodes are faulty the alternator will not generate any voltage When one or more diodes are faulty the alternator will produce too low voltage The flexible leads connected to the diodes should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward dir...

Page 37: ...fan heater or similar apparatus into the generator air inlets or outlets 5 4 Special procedures engine 5 4 1 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 nomina...

Page 38: ...egrees in normal and reverse direction of rotation Fig 29 Checking valve clearance turning If the rocker arms move piston no 1 is on the T D C of the intake or exhaust stroke In such case turn the crankshaft 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 cylinde...

Page 39: ...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 2 Taking the generator set from its mounting or to replace a mounting can be done according to the drawing below 3 Reassembling the generating set one should take care of alignment cleaning the surfaces between engine and alternator and tighten the bolts ...

Page 40: ...SPARE PARTS ...

Page 41: ...over type M16 10 50209018 Bolts cover 1 6 pcs 40206257 Repair kit A See next pages 40206258 Repair kit B See next pages 50201553 Heat exchanger complete with appendages 50201551 Water hoses with clamps 50209145 Measuring coil Wh 25 3 pcs 50208010 Rotary diode three phase 50208015 Alternator bearing including O ring 50208020 Voltage regulator 40209161 Local control panel 50209199 Digital Diesel Con...

Page 42: ...SPARE PARTS ...

Page 43: ...SPARE PARTS EN M SQ 27 August 2020 43 ...

Page 44: ...MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Page 45: ...NOTES EN M SQ 27 August 2020 45 NOTES ...

Page 46: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com info whisperpower com ...