USERS MANUAL FOR MOBILE APPLICATIONS W-SQ12 - 1500 RPM - Mobile diesel generating set 230V / 50Hz Digital Diesel Control Art.nr. 40200481 WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel.: +31-512-571550 Fax.: +31-512-571599 www.whisperpower.
TABLE OF CONTENTS TABLE OF CONTENTS: 1 INTRODUCTION .............................................................................................................................................................. 4 1.1 General .............................................................................................................................................................. 4 1.2 Service and maintenance ................................................................................................
TABLE OF CONTENTS 3 OPERATION .................................................................................................................................................................. 20 3.1 General ............................................................................................................................................................ 20 3.2 Operating Instructions ...................................................................................................................
INTRODUCTION 1 INTRODUCTION 1.1 GENERAL The W-SQ12 Mobile Diesel Generating set is manufactured and marketed by Whisper Power. It is important to read this manual before installing and operating the generating set. Both safety and durability rely very much on the correct identification, installation and a good understanding of ratings, features, design, maintenance and operation procedures.
INTRODUCTION The generator and other parts should be protected against the influences of the weather and splashing water (with dirt and salt) below the vehicle. Refer to the installation manual for instructions but remember these are for guidance only as many factors influence the installation of a generator. The ultimate responsibility will always be with the owner to ensure a safe and compliant installation.
INTRODUCTION 1.5.2 Identification plate 2 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. Power is rated at an ambient temperature of 25ºC. For higher temperatures the generating set has to be derated.
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-SQ12 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 08 09 10 11 12 13 14 Identification plate Digital Diesel Control (DDC) Control panel Fuses Fuel injector (4x) Glowplug (4x) Fuel injection pump Fuel solenoid Engine oil filter AC power output Remote control Power take off (PTO) Dry exhaust 1½” Expansion tank Ø8mm Fig.
INFORMATION 40 41 42 43 44 45 46 47 48 Exhaust manifold (watercooled) Filler cap engine coolant Rocker cover Filler cap engine oil Temperature switch coolant Thermostat housing Failsafe Air cleaner element Hoist eye rear Fig. 5: Top View main components W-SQ12 50 51 52 53 54 55 56 66 67 Exhaust manifold (watercooled) Rubber engine mounting Starter motor solenoid Starter motor Coolant generator out Water pump of the alternator cooling circuit V-belt Engine coolant pump Alternator (12VDC) 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. 2.4.3 Remote control panel 03 02 01 Engine The W-SQ12 generating set is based on the Mitsubishi S4L2 4 cylinder diesel engine. The engine is indirectly injected.
INFORMATION 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. This means that the generating set will not work when the alarm switches are broken or there is a loose wire. The system therefore is intrinsically safe. The panel will display details about the alarm.
INFORMATION 2.5.13 Technical data GENERAL Model RPM W-SQ12 1500 Alternator Engine water cooled, synchronous Mitsubishi diesel, model S4L2 (Japan) Number of cylinders Displacement 4 1758 cm3 Bore X stroke Combustion air consumption 78x92 mm 1.8 m³/min. Continuous power engine Cooling system 12 kW By means of a radiator. Fuel lift pump engine Starting battery (optional) electric pump (12 V DC), additional pump available upon request 85 Ah 12V Fuel consumption Control 2-5.
INFORMATION 2.5.
INFORMATION Optional control for two speeds fans. See chapter 2.5.17 2.5.
INFORMATION 2.5.
INFORMATION 2.5.17 Electrical diagrams radiator fan control MAIN CIRCUIT BREAKER L1 GENERATOR AC LOAD N CIRCUIT BREAKER AIR FANS 6A Fig. 12: Electrical diagram for standard fan control using 230V AC radiator fans BAT. +12V 4 FUSE 5A PUMP +12V 1 GENERATOR 230VAC (L1) 11 FUSE 6.
INFORMATION 2.5.18 Diagram electronic governor (standard) In addition to the mechanical governor, the W-SQ12 is 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 (1500 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, connecting the battery to earth and connecting the digital remote control panel. 1 2 Maximum oil level Minimum oil level 1 2 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. 4.2.7 Air filter element The interval for cleaning of the air filter element (figure 20) strongly depends on environmental conditions. Check the condition of the element at least every 500 running hours, but should be at least every six months. Fig. 18 4.2.
MAINTENANCE 4.3 REGULAR 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. CHECK DAILY: • Oil level (see fig. 22) Take care the oil level is never below the mark. Do not add oil when the level is still above the mark 1 2 Minimum oil level Maximum oil level Fig.
MAINTENANCE 4.3.1 Maintenance schedule 4.3.2 Check oil level daily Check the level of the cooling liquid daily Change oil and oil filter after first 50 hours Check and tighten nuts, bolts, etc.
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 5.1.2 Trouble shooting table alternator PROBLEM No output (Voltage) at all CAUSE • Circuit breaker "off" or faulty fuse • Low engine RPM. • Loss of residual magnetism. • Capacitor loose or broken. • Rotor diodes broken. Generator output voltage too low when no load is on it (less than 210V/105V)). • No load at all or very low load. • Engine is not reaching the rated RPM. • Defective capacitor.
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 General Most electrical problems relating to Voltage or Frequency are due to wrong engine speed. Note that RPM and Hz are basically the same. Use the problem solving table to find the cause of a wrong engine speed. When there is no obvious cause one can adjust the RPM (refer to special procedures).
TROUBLE SHOOTING 5.2.2 Trouble shooting table engine PROBLEM CAUSE SOLUTION Diesel engine fails to crank, the starter makes clicking noises, or the engine cranks very slowly • Almost certainly this is an electrical problem. Display will indicate “LOW START BAT” • Starter battery switched "OFF". The problem must be an electric malfunction. • Starter battery voltage (battery too weak).
TROUBLE SHOOTING PROBLEM CAUSE • 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 Drain oil to proper level Check fuel supply system: fuel pump and filter. Check air intake. Check the exhaust piping; inspect manifold inside Reduce the electrical load (switch off some consumers).
TROUBLE SHOOTING PROBLEM CAUSE • Fuel injector faulty. • Valve clearance incorrect. • 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.
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 a short circuit.
TROUBLE SHOOTING 5.4 SPECIAL PROCEDURES ENGINE TDC mark piston 1 5.4.1 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 Whisper Power Service Centre for advice Mark on timing gearcase IT (injection timing) mark TDC mark piston 2 and 3 Fig 27 5.4.
TROUBLE SHOOTING 5.4.3 Disassembling instructions It could be necessary to disassemble the generating set for repair or checks. Following instructions will help: 1 2 3 The design of the W-SQ12 makes it possible to do most repairs on the spot. The connections of the alternator are very accessible. The same is true for the diode of the rotor The sound shield can be disassembled according to exploded view below (figure 28).
SPARE PARTS LIST 6 SPARE PARTS LIST A complete parts manual in English is available as an option number: number: 40200383 (***) A work shop manual in English is available as an option number: 40200172 (***). 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. 40201460 article no.
SPARE PARTS LIST Figure 29: water pump complete Whisper Power type M12 36 50201811 Shaft 50209016 Circlip 50209014 Bearing 50221031 Male hose connector 50201414 Pump housing 50201814 O-ring 50209015 Seal 50209019 Circlip 50209019 Circlip 50209014 Bearing 50209015 Seal 50209017 O-ring January 2009 / W-SQ12 for mobile applications / EN 50201450 RAW WATER PUMP M12 50221007 Male hose connector Screw impeller 50209013 Impeller K+ M 50209012 Gasket 50201401 Cover type M12 50209018 Screw cover 50209011
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: next service (every 150 hours) hour counter: EN / W-SQ12 for mobile applications / January 2009 remarks 37
NOTES NOTES 38 January 2009 / W-SQ12 for mobile applications / EN
NOTES NOTES EN / W-SQ12 for mobile applications / January 2009 39
Kelvinlaan 82, 9207 JB Drachten, The Netherlands Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / info@whisperpower.