Whisper Power W-SQ-Pro, Installation Manual

Page 1: ...1 INSTALLATION MANUAL W SQ Pro 15kVA 18kVA 1500 RPM Mobile diesel generating set 230 400V 50Hz 1phase 3phase Digital Diesel Control WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands www whisperpower com V3 June 2021 Art no 40200484 ...

Page 2: ...19 3 1 General 19 3 2 Commission table 19 3 3 Technical data 20 3 4 Installation materials 21 4 DIAGRAMS DRAWINGS 26 4 1 Wiring colours W SQ PRO 15 1 phase 3 phase Mobile 26 4 2 Wiring colours W SQ PRO 18 1 phase 3 phase Mobile 27 4 3 Layout Generator Control W SQ PRO 15 1 Phase Mobile 30 4 4 Layout Generator Wiring W SQ PRO 15 3 Phase Mobile 33 4 5 Layout Generator Wiring W SQ PRO 18 1 Phase Mobi...

Page 3: ... 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 WARNING Before working installation on the system read the section safety instructions in the User Manual 1 2 GENERATING SETS FOR MOBILE LAND APPLICATIONS On mobile land applications the engine of the W SQ Pro 15 11 and W SQ Pro 18 15 5 are ...

Page 4: ...INTRODUCTION 4 June 2021 W SQ Pro 15 and W SQ Pro 18 Figure 2 Typical vehicle application radiator top mounted Figure 3 Typical vehicle application radiator bottom mounted ...

Page 5: ...ce side and on the top except for W SQ PRO 18 15 5 that has the oil filler cap only on top Cooling liquid can be filled via the expansion tanks The top of the engine rocker cover has to be accessible for adjustment of the valve clearance Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level is checked regularly 2 3 INSTRUCTIONS FOR OPTIMAL SOU...

Page 6: ...each temperature increase of 5 C reduces the engine power by about 2 In order to minimize these effects to the extent that the operator can influence them the temperature of the engine compartment must not exceed the temperature of the outside air by more than 15ºC Apply a combination of ventilators blowers and air intake ducting to meet the temperature limit The air inlet ducts should run to the ...

Page 7: ...SQ Pro 18 7 w Figure 6a Connections W SQ PRO 15 10 8 Three Phase Figure 6b Connections W SQ PRO 15 10 8 Three Phase 05 Fuel out 06 Fuel in 07 Dry exhaust 01 Remote control cable 02 AC power output 03 Battery cable 04 Battery cable ...

Page 8: ... SQ Pro 15 and W SQ Pro 18 Figure 7a Connections W SQ PRO 18 15 5 Three Phase Figure 7b Connections W SQ PRO 18 15 5 Three Phase 05 Fuel out 06 Fuel in 07 Exhaust 01 Remote control 02 AC power output 03 Battery cable 04 Battery cable ...

Page 9: ...gine fuel supply Driving the tank empty below the level of the suction pipe of the generator could make it necessary to bleed the fuel system 2 FUEL LIFT PUMP The generating set itself is equipped with a fuel lift pump therefore the tank can be installed at a lower level than the generating set See figure 9 The maximum suction height is 1 m The W SQ PRO 18 15 5 has a mechanical fuel lift pump that...

Page 10: ...el supply fuel tank is below the generating set 1 Fuel return 2 Fuel supply 3 Prefilter Water separator optional 4 Extra fuel lift pump optional 5 Fuel tank Figure 10 Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle A 1 3 2 5 4 ...

Page 11: ...hich requires maintenance WhisperPower advises to install an extra fuel filter water fuel separator near the fuel tank Before starting your generating set for the first time follow the fuel system bleeding procedure in the User Manual 2 3 3 Radiator cooling 1 GENERAL INSTRUCTIONS The radiators can be mounted below the floor in the side or on the roof of the mobile land applications It is recommend...

Page 12: ... to the expansion tank When the radiator is flat mounted on the roof the expansion tank should be mounted a little higher refer to figure 15 detail B Figure 15 Low profile radiator assembly on the roof Most cooling problems originate from air traps blocking the circulation of the engine coolant It is very important to use good quality heat resistant hose and fittings Therefore it is strongly advis...

Page 13: ...iator from rain and objects but must not block the airflow The fan should be inwards which causes the air to blow outwards A disadvantage of having the radiator in the side is possibly more noise of the electric fan and a flow of air that could be felt by people passing by A free flow of air should be guaranteed The ventilation connection of the cooling system that goes to the expansion tank shoul...

Page 14: ...rainwater to enter the system Special rain caps are available as an option Figure 22 Ways to prevent water to get in A negative feature of a dry exhaust system is the heat radiated by its components Measures are taken to overcome the heat problem The exhaust bent to bring the exhaust out of the canopy is cooled by water Insulation blankets are included in the exhaust kit to insulate the flexible b...

Page 15: ...ld be mounted according to the indication on the muffler itself The resonance muffler should be fitted according to direction of the gas flow indicated In the kit are clamps to mount the exhaust pipes to stainless steel bars These bars should be mounted to the chassis of the vehicle It is recommended to use rubber mountings whenever possible However take care that the heat conducted through the br...

Page 16: ... Fig 26 Connection for emergency stop fire alarm switch Automatic starting and stopping WhisperPower cannot be held responsible for damage caused by the unattended running generator using the auto start stop mode or interval mode 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 a...

Page 17: ... used to interrupt the positive connection The starter battery is charged by the alternator on the engine An additional battery charger will help to keep the battery in good condition when the generating set is not used A battery charger is not included in the standard supply A high efficiency battery charging unit can be ordered from WhisperPower which is able to charge both the mobile land appli...

Page 18: ...d neutral 1 FUSE The generating set are fitted with an integrated circuit breaker The current rating of this circuit breaker depends on the generator type see the table below for more details Model Maximum output current W SQ PRO 15 1phase 3phase 1 x 59 Amp 3 x 20 Amp W SQ PRO 18 1phase 3phase 1 x 76 Amp 3 x 25 Amp Output fuses and insulation guards between the generating set and the electrical in...

Page 19: ...efore or after the power source selector When there is only a circuit breaker use it to disconnect the generating set from the grid 7 Check all DC connections check if the battery switch circuit breaker is closed 8 Open the fuel valve Check if there are no air leaks in the fuel supply line and check if the lift of the fuel is less than 1 meter Check if there is no air in the water fuel separator 9...

Page 20: ...g Kwh 235 g Kwh full load Model fuel pump Facet Gold Flo Facet Gold Flo Max lift fuel pump 1m 1m Cooling Radiator cooling Radiator cooling Cooling pump WhisperPower self priming raw water impeller pump PTO driven Model cooling pump 6 520 ST 744 Minimum water supply 18 22 l min 20 25 l min Alternator Air cooled brushless four pole 6 or 12 wire synchronous Voltage regulation Automatic Voltage Regula...

Page 21: ...apter M6 BATTERY INSTALLATION KIT 100 Ah Art Nr 40290108 no qty article no description 52 1 61112007 WBC Handy 70 charger 12V 7A 53 1 40290094 Battery terminal PLUS 54 1 40290093 Battery terminal MINUS 55 1 40290091 Terminal Cover RED pos 56 1 40290092 Terminal Cover BLACK neg 57 1 50214701 WP Compact Manual Battery Switch 300A single circuit ON OFF 58 2 40290099 Battery pole adapter M8 BATTERY no...

Page 22: ... 2 50221531 Hose clamp RVS mini 7 9 10 8 50221522 Hose clamp RVS 16 11 1 50220063 Fuel Hose Filter Out 8x16mm L 700mm 12 1 50201164 Check valve fuel 8mm 421 99 0000 13 1 50201168 Facet Fuel Pump 12V Electric 14 2 50220063 Fuel hose 16x8 L 200 15 1 40209030 Fuel filter TOTAL 42401959 FUEL SUPPLY KIT Note fuel pipes fuel hoses are not included in the delivery of the fuel supply kit OPTIONAL INSTALLA...

Page 23: ...r SDHC 1 66 2 50221403 Pipe nipple 1 x300mm galvanized 67 2 50221423 Parallel male coupling 1 galvanized 68 2 50221413 Straight coupling f f 1 galvanized 69 3 50221663 U clamp 48 mm M10 70 3 50221664 Bracket U clamp 25cm 48 60 mm passivated 71 6 50211406 Washer SP M10 72 6 50211447 Washer spring SP M10 73 6 50211466 Nut hexagonal SP M10 75 1 50221473 Elbow 90 degr m f galvanized 1 76 2 50230518 Fi...

Page 24: ... 4 50201121 Vibration mounting 30x25mm 10 4 50211152 Bolt hexagonal ZP M8x16 11 4 50211465 Nut hexagonal SP M8 12 4 50211405 Washer SP M8 13 8 50211445 Washer spring SP M8 14 6m 50220013 Cooling water hose smooth 1 32x41mm 15 4 50221504 Hose clamp stainless 38 50 mm 16 8 50221597 Hose support stainless 45x20 mm 17 1 50230529 Bracket expansion tank for 50230531 pass 17 1 50230531 Expansion tank 20 ...

Page 25: ...s No Qty Article No Description 22 1 50230535 Expansion tank 7L low level alarm switch No Qty Article No Description 1 2 50200017 Hose I D 25mm 0 3 meter 2 2 50221025 Hose connector M 1 x25 3 2 50221014 Hose connector F 1 x35 4 2 50221503 Hose Clamp Stainless Steel 35mm TOTAL 40230655 Adjust kit 25mm to 35mm Generator to Radiator ...

Page 26: ...enerator R DDC hold 18 White 1 5 mm Gen D DDC hold Bridge Rectifier 18 Green 1 5 mm Bridge Rectifier Fuel Solenoid hold 18 Green 1 5 mm Bridge Rectifier Fuel Solenoid pull 19 Pink 2 5 mm DDC pull Bridge Rectifier 19 Pink 2 5 mm Fuel Pump LCP 20 Black 1 5 mm DDC gnd LCP 20 Black 1 5 mm Ground LCP 20 Black 1 5 mm LCP Temp Switch Exhaust 20 Black 1 5 mm LCP Temp Switch Coolant 20 Black 1 5 mm Ground ...

Page 27: ...e only Starter Motor Alternator 1 Red 10 mm Battery Starter Motor 1 Red 35 mm Starter Motor DDC 1 Red 6 mm Starter Motor LCP j4 1 Red 2 5 mm Generator EXC AVR m1 3 Black 1 5 mm Generator EXC AVR m3 4 Black 1 5 mm AVR m3 AVR m4 5 Black 1 5 mm Generator wt AVR m4 6 Black 1 5 mm Generator yl AVR m5 7 Black 1 5 mm Generator bk AVR m6 8 Black 1 5 mm Generator gn AVR m6 9 Black 1 5 mm Measuring Coil T1 ...

Page 28: ...3 Orange 1 5 mm Generator N Contact 3 23 Black 1 mm Generator N DDC ac1 24 Brown 6 mm Contact 3 Circuit Breaker 3 32 Yellow 1 mm Contact 4 Generator PE 33 Grey 1 mm Generator U DDC ac1 34 Red 1 mm Generator U Circuit Breaker 1 35 Green 1 mm Generator V Circuit Breaker 3 36 Pink 1 mm Generator V DDC ac2 37 Black 1 5 mm Generator W DDC ac3 38 Red Green 1 mm Generator W Circuit Breaker 5 39 Grey 1 5 ...

Page 29: ...6 mm Generator U DDC ac1 L1 1 Brown 1 5 mm Generator U Circuit Breaker 1 L1 1 Brown 6 mm Generator V Circuit Breaker 3 L2 1 Black 6 mm Generator V DDC ac2 L2 1 Black 1 5 mm Generator W DDC ac3 L3 1 Grey 1 5 mm Generator W Circuit Breaker 5 L3 1 Grey 6 mm Generator N DDC ac3 N 1 Blue 1 5 mm Generator N DDC ac1 N 1 Blue 1 5 mm Generator N DDC ac2 N 1 Blue 1 5 mm Generator N Contact 4 N 1 Blue 6 mm C...

Page 30: ...2020 0 5 6 WhisperPower Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 5 5 2020 ffokkema SOLIDWORKS Electrical G 1 2 3 4 L N 3 L 1 4 N 2 15kVA G1 230VAC 50Hz L N PE RD EXC BK EXC WT YL BK GN L1 1 PE 1 2 3 Y2 AVR Linz HVR 11 M1 M2 M2 M3 M3 M4 M4 M5 M5 M6 M6 M6 M6 M7 M8 4 4 3 3 6 6 7 7 8 8 9 9 5 5 L1 1 X12 T1 S1 S2 11 11 10 10 N 1 J2 DDC ENGINE CONTROLER 1Ph 04 1...

Page 31: ... Version REVISION LOCATION Document realized with version CONTRACT SCHEME CHANGES NAME REV DATE 1 2 3 4 5 6 7 8 9 10 04 L1 Generator Engine DC 7032 7032CD200505 NOT REQUIRED 0 2020 0 5 6 WhisperPower Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 5 5 2020 ffokkema SOLIDWORKS Electrical S2 G3 F5 G R L Alternator G2 M S M1 Starter motor 20 1 1 1 L2 Customer 18 P ...

Page 32: ...Generator Engine sensors 7032 7032CD200428 NOT REQUIRED 0 2020 0 3 7 WhisperPower Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 4 28 2020 ffokkema SOLIDWORKS Electrical 20 0 5 Bar 0 5 bar Oil pressure switch NO B3 J2 DDC ENGINE CONTROLER 3Ph 03 6 04 1 B1 Coolant temp 95 C 20 t 1 oil B5 Exhaust temp 110 C 20 t 2 Marine only t 2 t 1 oil 48 48 J5 47 47 46 46 110 ...

Page 33: ...ease 0 4 28 2020 ffokkema SOLIDWORKS Electrical G 5 6 7 8 12 4 3 2 1 10 11 9 V U W N 4 8 12 N W 9 5 V 1 U 10 11 6 7 2 3 15kVA G1 400VAC 50Hz U V W N PE RD EXC BK EXC WT YL BK GN L1 1 L2 1 L3 1 PE 1 C 25A Q1 1 2 3 4 5 6 7 8 4 5 Y2 AVR Linz HVR 11 M1 M2 M2 M3 M3 M4 M4 M5 M5 M6 M6 M6 M6 M7 M8 4 4 3 3 6 6 7 7 8 8 9 9 5 5 L1 1 L2 1 L3 1 X12 T1 S1 S2 T2 S1 S2 T3 S1 S2 11 11 15 15 12 12 10 10 13 13 N 1 J...

Page 34: ...rst Release 0 4 28 2020 ffokkema SOLIDWORKS Electrical S2 G3 F5 G D W Alternator G2 M S M1 Starter motor 20 1 1 1 L2 Customer 18 P M2 Fuel pump 20 20 20 17 17 J1 20 R1 J2 DDC ENGINE CONTROLER 3Ph 03 6 05 3 21 21 start hold 23 alt 24 24 glow fuel 1 st reg P1 Local Control Panel 1 37 37 38 38 39 39 20 20 49 49 Emergency Stop gnd 20 20 J4 J17 J19 J22 J21 J20 J10 J5 J11 J16 J15 J9 J14 J8 J13 J7 J18 J1...

Page 35: ...Generator Engine sensors 7032 7032CD200428 NOT REQUIRED 0 2020 0 3 7 WhisperPower Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 4 28 2020 ffokkema SOLIDWORKS Electrical 20 0 5 Bar 0 5 bar Oil pressure switch NO B3 J2 DDC ENGINE CONTROLER 3Ph 03 6 04 1 B1 Coolant temp 95 C 20 t 1 oil B5 Exhaust temp 110 C 20 t 2 Marine only t 2 t 1 oil 48 48 J5 47 47 46 46 110 ...

Page 36: ...08120 0 2020 0 2 9 WhisperPower Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 5 6 2020 ffokkema SOLIDWORKS Electrical G 1 2 3 4 L N 3 L 1 4 N 2 18kVA G1 230VAC 50Hz L N PE RD EXC BK EXC WT YL BK GN L1 1 PE 1 C 80A Q1 1 2 3 4 3 4 Y2 M1 M2 M2 M3 M3 M4 M4 M5 M5 M6 M6 M6 M6 M7 M8 4 4 3 3 6 6 7 7 8 8 9 9 5 5 L1 1 X12 T1 S1 S2 11 11 10 10 J2 DDC ENGINE CONTROLER 1Ph...

Page 37: ...s Drawing no Article no First Release 0 5 6 2020 ffokkema SOLIDWORKS Electrical S2 G3 F5 G R L Alternator G2 M S M1 Starter motor 20 1 1 1 L2 Customer 18 P M2 Fuel pump 20 20 20 17 17 05 1 J1 20 R1 J2 DDC ENGINE CONTROLER 1Ph 03 6 05 1 21 21 start hold 23 alt 24 24 glow fuel 1 J3 ECU V2203 05 6 18 20 15 16 23 26 1 19 H1 NO C 9 st reg 18 23 start hold alt gl st reg fuel P1 Local Control Panel 1 J4 ...

Page 38: ...Power Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 5 6 2020 ffokkema SOLIDWORKS Electrical 20 0 5 Bar 0 5 bar Oil pressure switch NO B3 04 10 J3 ECU V2203 04 6 J2 DDC ENGINE CONTROLER 1Ph 03 6 04 1 B1 Coolant temp 95 C 20 t 1 oil Y1 2 1 Governer B2 Coolant temp sensor 1 2 20 32 32 34 34 34 13 33 33 18 1 2 Pickup B4 3 20 35 35 36 36 17 20 B5 Exhaust temp 110 C...

Page 39: ...Release 0 3 24 2020 ffokkema SOLIDWORKS Electrical G 5 6 7 8 12 4 3 2 1 10 11 9 V U W N 4 8 12 N W 9 5 V 1 U 10 11 6 7 2 3 18kVA G1 400VAC 50Hz U V W N PE RD EXC BK EXC WT YL BK GN L1 1 L2 1 L3 1 PE 1 C 32A Q1 1 2 3 4 5 6 7 8 4 5 Y2 AVR Linz HVR 11 M1 M2 M2 M3 M3 M4 M4 M5 M5 M6 M6 M6 M6 M7 M8 4 4 3 3 6 6 7 7 8 8 9 9 5 5 L1 1 L2 1 L3 1 X12 T1 S1 S2 T2 S1 S2 T3 S1 S2 11 11 15 15 12 12 10 10 13 13 N ...

Page 40: ... Drawing no Article no First Release 0 3 24 2020 ffokkema SOLIDWORKS Electrical S2 G3 F5 G R L Alternator G2 M S M1 Starter motor 20 1 1 1 L2 Customer 18 P M2 Fuel pump 20 20 20 17 17 05 1 J1 20 R1 J2 DDC ENGINE CONTROLER 3Ph 03 6 05 1 21 21 start hold 23 alt 24 24 glow fuel 1 J3 ECU V2203 05 6 18 20 15 16 23 26 1 19 H1 NO C 9 st reg 18 23 start hold alt gl st reg fuel P1 Local Control Panel 1 J4 ...

Page 41: ...Power Kelvinlaan 82 9207JB Drachten The Netherlands Drawing no Article no First Release 0 3 24 2020 ffokkema SOLIDWORKS Electrical 20 0 5 Bar 0 5 bar Oil pressure switch NO B3 04 10 J3 ECU V2203 04 6 J2 DDC ENGINE CONTROLER 3Ph 03 6 04 1 B1 Coolant temp 95 C 20 t 1 oil Y1 2 1 Governer B2 Coolant temp sensor 1 2 20 32 32 34 34 34 13 33 33 18 1 2 Pickup B4 3 20 35 35 36 36 17 20 B5 Exhaust temp 110 ...

Page 42: ...DIAGRAMS DRAWINGS 42 June 2021 W SQ Pro 15 and W SQ Pro 18 4 7 ELECTRICAL DIAGRAMS RADIATOR FAN CONTROL 230VAC Fig 36 Electrical diagram for standard fan control using a 230 Volt AC radiator fan ...

Page 43: ...MS DRAWINGS 43 June 2021 W SQ Pro 15 and W SQ Pro 18 4 8 REMOTE CONTROL PANEL DRAWINGS Fig 38 Whisper remote panel The remote panel comes in a carton that can be used as a template to drill the mounting hole ...

Page 44: ...ECTIONS W SQ PRO 15 10 8 BOX DIMENSIONS W SQ PRO 15 10 8 Exhaust 1 Length 1145 mm Fuel hose 5 16 8 mm Width 625 mm Radiator engine 1 32 mm Height 690 mm Battery AWG 2 25 mm2 Weight 410 kg Battery AWG 2 25 mm2 POWERCABLES ISO 13297 annex A 3 x 10 mm2 or 5 x 4 mm2 not included REMOTE CONTROL 15 meter 8 wire communication cable included ...

Page 45: ...IONS W SQ PRO 18 15 5 Exhaust 1 Length 1220 mm Fuel hose 5 16 8 mm Width 719 mm Radiator engine 1 32 mm Height 754 mm Battery 35 mm2 Weight 510 kg Battery 35 mm2 A template to drill the mounting holes of the W SQ PRO 18 is included in the delivery POWERCABLES ISO 13297 annex A 3x16 mm2 not included REMOTE CONTROL 15 meter 8 wire communication cable included ...

Page 46: ...46 June 2021 W SQ Pro 15 and W SQ Pro 18 Notes ...

Page 47: ...1 1 1 1 1 1 1 1 1 1 1 1 1 2 Kelvinlaan 82 9207 JB Drachten Netherlands 1 1 1 1 1 1 2 1 www whisperpower com sales whisperpower com ...