Whisper Power m-sq20, User Manual

Page 1: ... 1500 RPM Marine diesel generating set 230 400V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 November 2010 Art nr 40200441 ...

Page 2: ...in the standard delivery 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 13 2 5 3 Digital Diesel Control system 13 2 5 4 Battery charger 13 2 5 5 Alarms and shut down 13 2 5 6 Monitoring 13 2 5 7 Control 14 2 5 8 Remote control 14 2 5 9 Hour counter 14 2 5 10 Load indicator ...

Page 3: ... 26 5 TROUBLE SHOOTING 27 5 1 Alternator electrical faults 27 5 1 1 General 27 5 1 2 Trouble shooting table 27 5 2 Engine faults 28 5 2 1 General 28 5 2 2 Trouble shooting table 29 5 2 3 Warnings 32 5 2 4 Service address 32 5 3 Special procedures alternator 32 5 3 1 Automatic Voltage Regulator AVR 32 5 3 2 Residual voltage check excitation procedure flashing 33 5 3 3 Testing rotary rectifier diode...

Page 4: ...nd 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 The well functioning of this gene...

Page 5: ...ed 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 ca...

Page 6: ...y the speed of the 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 installat...

Page 7: ...es 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 Recrea...

Page 8: ...on Do not smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand INCASEOFFIRE DONOTOPENSOUNDSHIELD TOAVOIDSERIOUSINJURYORDEATHFROM FIRE IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS SHUTDOWNENGINES GENERATORSETSANDBLOWERS PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT THROUGH HERE FIREEXTINGUISHERPORT BREAK Fig 3 Fire extinguisher port In case of fire do...

Page 9: ...n a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base The complete set is again on rubber mountings All cables and hoses are guided through the capsule s sides The set is not self contained and is only operable after proper installation using additional accessories and installation materials Installation acces...

Page 10: ... 25 01 Thermostat 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: ...oid 32 Oil filter 33 Injection pump air bleeding screw 34 Fuel lift pump for manual primimg 35 Fuel injection pump 36 Heat exchanger 37 Temperature switch 38 Hoist eye front 39 Alternator 40 Exhaust manifold watercooled 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: ...constant the average voltage of one phase The voltage setting on the AVR can be adjusted with the help of a trimmer V between 185 and 290 Volts See par 5 3 1 A frequency control progressively deactivates the machine when the drive motor speed drops below a pre set adjustable threshold preventing over excitement at low operating speeds and abating the load engage effects on the engine The AVR works...

Page 13: ...engine is indirectly injected The engine is water cooled and the cooling liquid is cooled by a heat exchanger and raw sea 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 copper nickel The engine has been specially adapted for the WhisperPower application and is very different from the stand...

Page 14: ...sumption 2 Oil viscosity We recommend a multigrade oil 15W40 3 Oil capacity Excluding the oil filter the content of the crankcase is 9 l Including the oil filter it is 9 3 l 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 detrime...

Page 15: ...CAL SPECIFICATIONS Output voltage 230 400V 50 Hz alternating current AC tri phase re connectable to take off single phase or dual voltage Output rating 50Hz 25kVA at powerfactor 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 b...

Page 16: ...INFORMATION 16 November 2010 M SQ20 25 EN 2 5 15 Electrical diagram control wiring M SQ20 25 Fig 13 Electrical Diagram control wiring M SQ20 25 ...

Page 17: ...INFORMATION EN M SQ20 25 November 2010 17 2 5 16 Terminal modes 115VAC 230VAC 400VAC 50H Fig 14 Terminal modes ...

Page 18: ...November 2010 M SQ20 25 EN 2 5 17 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR REFERTO2 1 3 USERMANUALWHISPER25U TOCONNECTNEUTRALTOGROUND Fig 15 Generator Diagram 3 phase with AVR 230V 400V 50Hz with AVR ...

Page 19: ...SQ20 25 November 2010 19 2 5 18 AC Wiring Diagram single phase with AVR 230V Hz Double Delta TOCONNECTNEUTRALTOGROUND REFERTO2 1 3 USERMANUALWHISPER25U Fig 16 AC Wiring Diagram single phase with AVR 230V Hz Double Delta ...

Page 20: ...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...

Page 21: ...able to recognise the coolant flowing through the system by listening for the noise of the water which is expelled Be aware that especially in harbours the coolant water inlet can easily be blocked by floating objects 4 Power source selector switch off shore power generator power Switch to power source generator If a Masterswitch is installed this operates automatically Before loading the generati...

Page 22: ... 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 com...

Page 23: ...e 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 s...

Page 24: ...ilter 02 Engine oil dipstick 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 ...

Page 25: ...t 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 screwdriver...

Page 26: ...t 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 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 ca...

Page 27: ...49 5 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 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 wi...

Page 28: ...ssary capacitor specification and replace AVR if necessary see special procedures Generator output voltage too high more than 235V In no load condition it is OK Unbalanced load Bring load in balance When slightly out of balance remove the sense wires to the phase with the highest load and check if the voltage on the other phases is not too low Generator voltage fluctuates Disturbances on the elect...

Page 29: ...ter in the cylinders or there is other severe damage Display will indicate low battery voltage 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 Fi...

Page 30: ...om fuel system see maintenance section 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 blo...

Page 31: ...dicate 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 running with very low load I...

Page 32: ...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 change...

Page 33: ...nit When all diodes are faulty the alternator will not generate any voltage When one or more diodes are faulty the alternator will produce too low voltage The flexible leads connected to the diodes should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in t...

Page 34: ...a 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 nomi...

Page 35: ...ned about 20 degrees 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 rem...

Page 36: ...rating set Following instructions will help 1 The design of the M SQ20 25 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 2 The sound shield canopy can be disassembled according to exploded view below Fig 31 Exploded view soundshield ...

Page 37: ...ut of its capsule is by lifting the set with the aid of the lifting eyes 4 Taking the generator set from its mounting or to replace a mounting can be done according to the drawing below Fig 32 Exploded view rubber mountings 5 Reassembling the generating set one should take care of alignment cleaning the surfaces between engine and alternator and tighten the bolts crosswise and gradually 6 Test the...

Page 38: ... Cover 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 C...

Page 39: ...SPARE PARTS EN M SQ20 25 November 2010 39 ...

Page 40: ...SPARE PARTS 40 November 2010 M SQ20 25 EN ...

Page 41: ...MAINTENANCE LOG EN M SQ20 25 November 2010 41 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Page 42: ...NOTES 42 November 2010 M SQ20 25 EN NOTES ...

Page 43: ...MAINTENANCE LOG EN M SQ20 25 November 2010 43 NOTES ...

Page 44: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl ...