Whisper Power W-SC3 User Manual

Page 1
USERS MANUAL FOR MOBILE APPLICATIONS
W-SC3
- 3000 RPM -
Mobile diesel generating set 230V / 50Hz
Digital Diesel Control
V1. January 2011
Art.nr. 40200309
Page 2
CONTENTS
2 January 2011 / W-SC3 Mobile / EN
CONTENTS:
1
INTRODUCTION .............................................................................................................................................................. 4
1.1 General .............................................................................................................................................................. 4
1.2 Service and maintenance ................................................................................................................................... 4
1.3 Guarantee .......................................................................................................................................................... 4
1.4 Liability ............................................................................................................................................................... 5
1.5 Identification ....................................................................................................................................................... 5
1.5.1 General .............................................................................................................................................. 5
1.5.2 Nameplate ......................................................................................................................................... 5
2 INFORMATION ................................................................................................................................................................ 6
2.1 Safety ................................................................................................................................................................. 6
2.1.1 General .............................................................................................................................................. 6
2.1.2 Electrical safety ................................................................................................................................. 6
2.1.3 Earth insulation failures ..................................................................................................................... 7
2.1.4 Installation ......................................................................................................................................... 7
2.1.5 Operation ........................................................................................................................................... 7
2.1.6 Fire and explosion ............................................................................................................................. 7
2.1.7 Chemicals .......................................................................................................................................... 7
2.2 Transport, lifting and storage .............................................................................................................................. 8
2.3 The W-SC3 mobile ............................................................................................................................................. 8
2.3.1 Features ............................................................................................................................................ 8
2.3.2 Remote control .................................................................................................................................. 8
2.3.3 Documentation .................................................................................................................................. 8
2.3.4 Accessories included in the standard delivery ................................................................................... 8
2.4 Components ....................................................................................................................................................... 9
2.4.1 Main components to identify .............................................................................................................. 9
2.4.2 Generator control panel ................................................................................................................... 10
2.4.3 Remote control panel ...................................................................................................................... 10
2.5 Technical Information ....................................................................................................................................... 10
2.5.1 AC alternator ................................................................................................................................... 10
2.5.2 Engine ............................................................................................................................................. 10
2.5.3 Digital Diesel Control system ........................................................................................................... 10
2.5.4 Battery charger ................................................................................................................................ 11
2.5.5 Alarms and shut down ..................................................................................................................... 11
2.5.6 Control ............................................................................................................................................. 11
2.5.7 Remote control ................................................................................................................................ 11
2.5.8 Hour counter .................................................................................................................................... 11
2.5.9 Load indicator .................................................................................................................................. 11
2.5.10 Fuel specification ............................................................................................................................. 11
2.5.11 Oil information ................................................................................................................................. 11
2.5.12 W-SC3 oil cooler.............................................................................................................................. 11
2.5.13 Alternator cooling............................................................................................................................. 12
2.5.14 Technical data ................................................................................................................................. 12
2.5.15 Wiring codes and colours ................................................................................................................ 13
2.5.16 DC wiring diagrams ................................................................... Fout! Bladwijzer niet gedefinieerd.
2.5.17 Electrical diagram 230 V AC / 50 Hz ............................................................................................... 15
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CONTENTS
EN / W-SC3 Mobile / January 2011 3
3 OPERATION .................................................................................................................................................................. 16
3.1 General ............................................................................................................................................................ 16
3.2 Operating Instructions ...................................................................................................................................... 16
3.2.1 Summarised operating instructions (daily use) ................................................................................ 16
3.2.2 Extended operating instructions ...................................................................................................... 16
4 MAINTENANCE ............................................................................................................................................................. 18
4.1 Alternator .......................................................................................................................................................... 18
4.2 Engine .............................................................................................................................................................. 18
4.2.1 Preliminary instructions ................................................................................................................... 18
4.2.2 Bleeding fuel lines ........................................................................................................................... 18
4.2.3 Valve clearance ............................................................................................................................... 18
4.2.4 Replacing fuel filter .......................................................................................................................... 19
4.2.5 Cleaning oil strainer ......................................................................................................................... 19
4.3 Regular maintenance ....................................................................................................................................... 19
4.3.1 Maintenance schedule ..................................................................................................................... 20
4.3.2 Putting out of service ....................................................................................................................... 20
5 TROUBLE SHOOTING .................................................................................................................................................. 21
5.1 Alternator/ electrical faults ................................................................................................................................ 21
5.1.1 General ............................................................................................................................................ 21
5.1.2 Trouble shooting table ..................................................................................................................... 21
5.2 Engine faults ..................................................................................................................................................... 22
5.2.1 General ............................................................................................................................................ 22
5.2.2 Trouble shooting table ..................................................................................................................... 22
5.2.3 Warnings ......................................................................................................................................... 25
5.2.4 Service address ............................................................................................................................... 25
5.3 Special procedures alternator ........................................................................................................................... 25
5.3.1 Residual voltage check / excitation procedure ................................................................................ 25
5.3.2 Testing rotary rectifier diodes .......................................................................................................... 25
5.3.3 Winding resistant values .................................................................................................................. 25
5.3.4 Meggering ....................................................................................................................................... 26
5.4 Special procedures engine ............................................................................................................................... 26
5.4.1 Setting the RPM .............................................................................................................................. 26
5.4.2 Tightening torques ........................................................................................................................... 26
5.4.3 Disassembling instructions .............................................................................................................. 26
6 SPARE PARTS LIST ..................................................................................................................................................... 27
MAINTENANCE LOG ............................................................................................................................................................... 29
Page 4
INTRODUCTION
4 January 2011 / W-SC3 Mobile / EN
1 INTRODUCTION
1.1 GENERAL
The W-SC3 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. The information, specifications, illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press. Our policy is one of continued development and we re­serve the right to amend any technical information with-out prior notice. Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer, distributor, or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof.
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.
DANGER
This danger symbol refers to electric danger and draws attention to special 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. injury or loss of life.
Realise that people are not used to have 230V available on a vehicle. Put warning signs on wall sockets and on junction boxes. Instruct non-regular users of the vehicle. Warn maintenance personal of garages that do service on the vehicle.
1.2 SERVICE AND MAINTENANCE
Regular service and maintenance should be carried out according to the directions in this manual. For service and maintenance one can appeal to the manufacturer or the dealers.
1.3 GUARANTEE
Whisper Power 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 functioning of this generating set is subject to guarantee. The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries for the North of the Netherlands number 01120025 and are available on request. The guarantee period is two years, limited to 1000 running hours. Some aspects of our warranty scheme are given here in more detail:
Guarantee period 1000 running hours or 24 months, whichever occurs first. Warrantee does not cover failures that are caused by misuse, neglect or a faulty installation.
Example 1: Faulty installation: Overheating of the engine or alternator is the most common cause of problems with mobile generating sets. These problems are caused by poor circulation of the cooling liquid due to wrong routing of the pipes to the radiator: bents will capture air bubbles causing “air-lockes” blocking the circulation of the liquid. Other examples of installation problems are hot air circulation into the radiator and the radiator fan sucking exhaust gasses into the radiators. 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 the installation manual.
Example 2: Misuse: Long term running with no load or too little load can cause the exhaust to get choked with soot or carbon. Cleaning the exhaust is not covered by warrantee.
Example 3: Neglect Whisper generators have an option for an auto start/stop mode or interval mode. Whisper Power cannot be held responsible for damage caused by the unattended running generator.
Warranty means that faulty parts are repaired or replaced free of charge. If necessary the whole generator unit will be exchanged. Labour necessary to complete repairs on board a vehicle executed by an authorized service
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INTRODUCTION
EN / W-SC3 Mobile / January 2011 5
engineer is covered, but is limited to a reasonable number of hours and reasonable rates in relation to the actual repair work that has to be done. Travel expenses and travel hours are not covered. Also not covered is the labour required to take a generator out of a vehicle or for reinstallation. There is no cover for labour needed to get access to the generator, for example to remove equipment or parts of the vehicle body etc.
Goods to be delivered under warrantee will be invoiced. Only after the faulty goods are returned will the invoice be credited. Payment in advance may be required or guaranteed by credit card. If after the faulty goods are returned, it is indicated that the failure was not covered by warranty a credit will not be issued. For example if a Printed Circuit Board is returned with clear damage caused by water, warranty will be refused. Freight costs to deliver spares by normal mail or carriers is covered under warranty. 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 warranty.
Additional agreements could be part of the contract of delivery.
If any problem arises which could be subject of guarantee, procedures should be followed as described in the guarantee certificate, unauthorised repairs could lead to further damage and violate the guarantee conditions.
Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this user’s manual and the supplementary installation manual, then damage may occur and the generating set may not fulfil its specifications. In all these cases the guarantee may become invalid. Use original spares only!
1.4 LIABILITY
Whisper Power does not accept responsibility for damage, injuries or casualties which are the result of operation of the generating set in specific conditions which brings dangers which could not be foreseen, or could be avoided by additional measures. Whisper Power does not accept liability for damage due to use of the generator, possible errors in the manuals and the results thereof.
Automatic start/stop Whisper Power cannot be held responsible for damage caused by the unattended running generator using the auto-start/stop mode or interval mode.
1.5 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.
1.5.2 Nameplate
All required identification data are on the nameplate.
1 The identity of the generating set is given by the
SERIAL NUMBER. When this number is available the manufacturer can trace the specifications of the generating set. On the nameplate are also some basic features of the set:
2 POWER
The nameplate gives the nominal maximum 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 in kW as shown on the nameplate. Power is rated at an ambient temperature of 25°C. For higher
Model W-SC3
Article number 40900620
Serial number
Max. power 3 KVA cos phi =0,8
2.5 KVA cos phi = 1
Voltage 230V ± 5%
Frequency 50 Hz
Current 11A
Phase Single phase
Dimensions L x W x H
505x400x500mm
Weight 97 kg
Fig 1: Nameplate
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INFORMATION
6 January 2011 / W-SC3 Mobile / EN
temperatures the generating set has to be derated. To drive the radiator fan (230 V fan) output could be taken from power generated by the genset. In that case nett power will be less than 3 kW.
3 VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance at the nominal frequency.
4 FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 50 Hz correlates with 3000 rpm, 60 Hz correlates with 3600 rpm.
5 CURRENT shows the maximum current that is
acceptable at the specified frequency, voltage and power factor.
6 WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and external installation equipment
7 The CE symbol shows that the generating set is build
according to European Community safety regulations. This includes the regulations regarding the safety of pleasure craft, machinery, electric safety and electric magnetic compatibility (EMC) and other relevant directives.
Safety also relies on the installation, application and circumstances. See also the remarks in this manual under SAFETY
Before changing a factory setting you are advised to consult the manufacturer. When the generating set you have to identify is not new you have to take into account the possibility that former users may have changed the settings. Check the settings (voltage, frequency, rpm) when there is any doubt.
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 gasses etc
2.1.2 Electrical safety
The voltage of 230 Volt generated by this generating set is dangerous and if instructions and procedures are not strictly observed may result in electrical shock which will result in severe personal injury or loss of life.
Realise that people are not used to have 230V available on a vehicle. Put warning signs on wall sockets and on junction boxes. Instruct non-regular users of the vehicle. Warn
maintenance personal of garages that do service on the vehicle.
Check all wiring at least once a year. Defects, such as loose connections, burned cables etc. must be repaired immediately.
Do not work on the electrical system if it is still connected to a current source. Only allow changes in your electrical system to be carried out by qualified electricians.
Connection and protection must be done in accordance with local standards.
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 and the battery plus cable must be removed from the battery.
Warning signs indicate parts which could be live.
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INFORMATION
EN / W-SC3 Mobile / January 2011 7
2.1.3 Earth insulation failures
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.
In all situations the transfer switches between shore, inverter and generator should switch both neutral and L1. Of course this is the case when using a Mastervolt Masterswitch.
2.1.4 Installation
Whisper generating sets are not self contained and have to be properly installed in enclosed areas. Installation includes measures to be taken to outlet exhaust fumes which contain carbon monoxide and are extremely dangerous. Carbon monoxide (CO) is an invisible odourless gas. Inhalation produces headache, nausea or death. Installation includes measures for proper ventilation, safe electric connections, safe installation of the starting battery, proper fitting of the cooling system and fuel pipes etc. Refer to the installation manual.
Do not use the generator set when the vehicle is inside a building or in other enclosed area’s. Be aware using the generator in wind still conditions, when the exhaust fumes could accumulate under, around or even in the vehicle.
2.1.5 Operation
The W-SC3 generating set does not have any external moving parts like fans and V-belts and therefore is very safe.
Nevertheless take note of the signs on the generating set which show symbols in a triangle indicating danger.
The generating set should be operated by authorised personnel only.
Be aware of hot parts and especially parts of the exhaust system.
If the generating set is unsafe, fit danger notices and disconnect the battery positive (+) lead so that it cannot be started until the condition is corrected.
Do not attempt to operate the generating set with a known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or cleaning inside the enclosure.
Always consult the manual before carrying out maintenance.
Do not change the settings without consulting the manufacturer. Keep a record of setting changes in this manual.
2.1.6 Fire and explosion
Fuels can be flammable. Proper handling limits the risk of fire and explosion.
Avoid refilling the fuel tank while the engine is running. When oil or fuel is leaking do not use the generating set.
Do not run the engine close to explosives or gasses.
Hydrogen gas generated by charging batteries is explosive. Ensure for proper ventilation. Do not smoke or allow sparks, flames, or other sources of ignition around batteries.
Keep a fire extinguisher 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 manufactured from asbestos. Particles of this material should not be inhaled as this may result in fatal diseases.
On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter the blood stream with fatal results.
Engines may be fitted with seals or O-rings manufactured from "viton" or similar material. When exposed to abnormal high temperatures in excess of 400°C an extremely corrosive acid is produced which cannot be removed from the
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INFORMATION
8 January 2011 / W-SC3 Mobile / EN
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
Included in the delivery is a lifting eye, 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.
Long term storage can have detrimental effects on engine and alternator. The engine should be put through an engine preservation procedure. (Refer to the maintenance chapter)
The alternator windings tend to condense. To minimise condensation, store the generating set in a dry and warm storage area.
After removing the generating set from long term storage perform an insulation check. (Refer to the alternator maintenance paragraph for procedures)
While the battery is stored it should be recharged every 12 weeks.
2.3 THE W-SC3 MOBILE
2.3.1 Features
This generating set includes a diesel engine which is connected by close coupling to an alternator in 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. 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 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 (refer to Digital Diesel Control user manual).
2.3.2 Remote control
The full automatic remote control panel including 10 mtr cable comes as standard with the W-SC3.
2.3.3 Documentation
Included in the delivery is this user manual (number:
40200309) an installation manual (number: 40200319) and a user manual for DDC (number: 40200261). Not included in the standard delivery but available as options are:
Parts manual; number: 40200180
Workshop manual; number: 40200170
However in this manual there is a list of important parts for maintenance and spare parts as well as a chapter on maintenance and problem solving.
2.3.4 Accessories included in the standard delivery
Fuel filter
Fuel lift pump
Lifting eye
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INFORMATION
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2.4 COMPONENTS
2.4.1 Main components to identify
1 Air inlet; 2 Starter motor; 3 Battery connection (positive); 4 Battery connection (negative); 5 AC 230 V wiring; 6 AC 230 V output connection box; 7 Fuel filter; 8 Fuel pipe inlet; 9 Fuel pipe return; 10 Cooling water out; 11 Cooling water in; 12 Exhaust manifold (water cooled); 13 -­14 Glow plug; 15 Injector; 16 Valve cover; 17 Decompression handle; 18 Oil filler cap; 19 Solenoid fuel valve; 20 Electric fuel lift pump; 21 Cooling water pump; 22 Oil pressure pump; 23 Fuel pressure pump 24 Oil pressure switch; 25 Oil sump pump; 26 Exhaust connection; 27 Fuel return; 28 Oil filler cap/ oil level indicator; 29 Control panel; 30 Capacitor; 31 Fuse 1; 32 Fuse 2; 33 Remote control cable; 34 Stop solenoid; 35 Oil strainer cover; 36 Start button; 37 Digital Diesel Control unit; 38 RPM set screw; 39 Alternator temp switch; 40 Plug screw; 41 Fuel lift pump cable; 42 Oil pump out (RED) 43 Oil pump in (BLACK)
Fig. 2: Overview W-SC3
18
19
27
25
40 23
38
37 30
29 31 32
36
34
24 28
1
39
14
2
41
20
7
26
3
9
4
10
11
6
1
17
15
16
12
3
4
21
22
35
33
5
8
43
42
41
24
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INFORMATION
10 January 2011 / W-SC3 Mobile / EN
2.4.2 Generator control panel
Fig. 3: Control panel.
1 Fuse 3A; 2 Fuse 3A; 3 Start/stop button.
Fig. 4: Digital Diesel Control unit
2.4.3 Remote control panel
1 Start button; 2 Stop button; 3 Select button; 4 Set button; 5 Failure lamp; 6 Generator load indicator. 7 Display
2.5 TECHNICAL INFORMATION
2.5.1 AC alternator
The single phase alternator is directly coupled, one bearing, brushless, rotating field design, two poles (3000 RPM) and self regulating. 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 feed back effect between rotor and stator. The field windings in the rotor are short-circuited over a diode to rectify the current. A capacitor over an additional winding in the stator which is at an angle with the power-winding keeps the voltage stable within 5 % at the specified rpm and provides voltage fall off with speed, preventing over-excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine. Further technical data on the design of the alternator can be found in drawings and diagrams in this manual. The alternator is water cooled and the cooling liquid is cooled by a radiator.
2.5.2 Engine
The W-SC3 generating set is based on the Kubota OC60 1 cylinder diesel engine. The engine is indirectly injected. The engine is oil cooled and the oil is cooled by a radiator. The engine has been specially adapted for the Whisper Power application and is very different from the standard engine supplied for industrial applications!
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt negative earth, non earth return (ungrounded) is available as optional. Check your identification data to determine which system is applied. The system is designed according to the "energise to run" system. The Digital Diesel Control is a very advanced microprocessor based full automatic system. Besides automatic start the system offers many monitoring options. Refer to the separate Digital Diesel Control user manual.
The microprocessor unit is located on top of the alternator.
1
2
3
3A 3A
Fig. 5: Digital Diesel remote control panel.
1 2 6 5
3 4 7
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INFORMATION
EN / W-SC3 Mobile / January 2011 11
2.5.4 Battery charger
There is an extra winding in the alternator generating 6 Amp 12 V. This current is rectified on the control PCB to charge the battery. Both the current and the voltage are regulated.
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the failure light and details will be shown on the display the engine will be shut down. There are three functions guarded: oil pressure, oil temperature and exhaust temperature. Exhaust temperature too high indicates the cooling water to be blocked or a faulty impeller. All alarm switches are closed when no malfunction occur. 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.
2.5.6 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 engine automatically. Pushing the STOP button will stop the engine and the electrical system will be deactivated. Stopping the engine is executed by the ‘pull’ solenoid, at the same time the fuel valve solenoid will shut off.
2.5.7 Remote control
All wiring connections from the remote control to the board are made by plug in connectors. An intermediate communication cable is in the standard supply. If necessary an optional longer 8 wire cable can be connected if the standard length does not suit the required distance. Numerous remote control units can be put in parallel by using the connectors on the back of the units. (Refer to installation instructions)
2.5.8 Hour counter
The remote control offers several timer functions that helps to schedule maintenance.
2.5.9 Load indicator
On the remote control the load will be indicated on the display and by the LED-bar. The load is measured by a current transformer on the alternator.
2.5.10 Fuel specification
The engine must only be used with diesel fuel oil which conforms to the standards for use in modern diesel engines. Fuel free from water and contaminants is of the utmost importance.
2.5.11 Oil information
1 Specification:
The oil must be suitable for oil changes as specified in the maintenance chapter. The Kubota engine must be run on heavy duty lubricating oil meeting the requirements of API class CD, CF or CF_4.
It is very important to use the correct oil specification. Very often local oil suppliers recommend a higher class, because they assume that a higher class is allowed. This is not the case. One should not follow these recommendations. Using the wrong specification will cause high oil consumption.
2 Oil viscosity:
We recommend a multigrade oil 15W40.
3 Oil capacity:
Excluding the oil cooler the content of the crankcase is 1,3 l. including the oil cooler it is 1,5 l.
Do not overfill with lubricating oil as this may have a detrimental effect on engine performance.
4 Oil pressure
Minimum at idle 49 Kpa (0,5 kgf/cm2 - 7psi).
Normal at 3000 rpm between 147 and 490 Kpa
(1,5 up to 5 kgf/cm2 - 21 up to 71 psi).
Minimum at 3000 rpm 98 Kpa (1,0 kgf/cm 2 - 14 psi).
2.5.12 W-SC3 oil cooler
The W-SC3 engine is cooled by oil and not by cooling liquid. The oil cooling radiator of the W-SC3 is not ventilated. The system is ventilated by the engine itself and no expansion tank is applied. To prevent the oil in the radiator - when mounted higher than the engine - to flow to the engine after stopping the engine (overflow the engine), a pressure valve has to be fitted (refer to figure 6).
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12 January 2011 / W-SC3 Mobile / EN
When it is not possible to drain the oil from the radiator every time the oil is changed, one should pump out the engine oil as good as possible from the engine sump and increase the oil change intervals to every 50 running hours.
2.5.13 Alternator cooling
The alternator is cooled by cooling liquid. The capacity of the system depends on the capacity of the radiator piping and other parts of the cooling system. We recommend not using water but cooling liquid that is marketed for the use in combustion engines. Cooling liquid protects the system against frost until minus 25° C. Also it protects the system against corrosion. Filling of the alternator cooling system has to be done via the expansion tank. When the system is on temperature the liquid will expand and the redundant liquid will be pressed into the expansion tank. This tank has to be filled up till the mark. On the tank is an overflow connection. This should be open. A hose can be connected to drain the overflow to outside the vehicle. When cooling liquid is not available clean fresh water could be used with an additive of anti freeze. When using water with anti freeze the right mixture has to be calculated according to the information of the supplier of the anti freeze. The cooling system is not pressurised.
2.5.14 Technical data
GENERAL
Model W-SC3 mobile
RPM 3000
Alternator water cooled, synchronous
Engine Kubota diesel, model OC60 (Japan)
Number of cylinders 1
Displacement 276 cm3
Bore X stroke 72x68 mm
Combustion air consumption 0,38 m3/min. at nominal RPM
Continuous power engine 2,5 kW
Cooling system Oil cooling by radiator
Cooling water pump PTO driven Whisper Power self priming impeller pump, type K
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 55-90 Ah
Fuel consumption 0.7-1.4 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 230V 50 Hz alternating current (AC) single phase
Output rating 3,6 KVA cos phi = 0,8; 3 KVA = 3 kW cos phi = 1
Voltage tolerance ± 5%
Frequency tolerance ± 5%
Alternator brushless, two pole, synchronous
valve
,
Figure 6: Pressure valve in the return line to prevent th e engine to overflow as a result of siphoning
W-SC3
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INFORMATION
EN / W-SC3 Mobile / January 2011 13
MECHANICAL SPECIFICATIONS
Supply includes generating set, built into tugged GRP sound shield with steel base frame, mounted
on rubber anti vibration mounts
Dimensions hxwxd 500x505x405 mm
Colour top white, bottom green
Weight 97 kg including sound shield
Max. installation angle 25 degrees
Standard supplies Digital Diesel Control, remote panel (10 m cable)
Optional Non earth return (ungrouded), spare part kits
2.5.15 Wiring codes and colours
number colour cable code no
cross section
battery > starter motor red 16 mm2
starter motor > DDC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 16 mm2
ground > LCP ground (GND) 2 black 2,5 mm2
DDC > glow plug 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 brown 1,5 mm2
LCP > fuel lift pump – 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
DDC > oil temperature switch 7 blue 1 mm2
LCP > oil temperature switch 7 blue/black 1 mm2
DDC > exhaust temperature switch 8 blue/green 1 mm2
LCP > exhaust temperature switch 8 blue/pink 1 mm2
DDC > fuel valve solenoid 9 green 1,5 mm2
DDC > stop solenoid 20 pink 2,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 19 orange 1,5 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
DDC=Digital Diesel Control Unit LCP=Local Control Panel
Page 14
INFORMATION
14 January 2011 / W-SC3 Mobile / EN
2.5.16 DC wiring diagrams
Fig. 7
Page 15
INFORMATION
EN / W-SC3 Mobile / January 2011 15
2.5.17 Electrical diagram 230 V AC / 50 Hz
Fig 8: Electrical diagram 230V
STATOR
ROTOR
L1
N
PE
EARTH AND NEUTRAL CONNECTED
230V 50Hz
PE
N
L1
EARTH AND NEUTRAL NOT CONNECTED
BLACK
TRANSFORMER
YELLOW/GREEN
CAPACITOR
MAIN WINDING
MAIN WINDING
(4)
(3)
(4)
CURRENT
CHARGER
WINDING
EXCITATION
BATTERY
(3)
(2)
(1)
RED
(10)
(10)
BLUE
BROWN
ALT
YELLOW/GREEN
ALT
REGULATOR
WCH
J1
J2
(11) (11)
DCC/ct-1
DCC/AC-1
BROWN (33)
BLUE (33)
BLUE (33)
BROWN (33)
DCC/AC-1
YELLOW/GREEN
BLUE
YELLOW/GREEN
BROWN
BLACK
DCC/ct-1
RED (11) (11)
TRANSFORMER
CURRENT
EARTH AND NEUTRAL CONNECTED
Page 16
OPERATION
16 January 2011 / W-SC3 Mobile / EN
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.
1 Filling cap 2 Minimum oil level 3 Maximum oil level
Figure 9:
3.2 OPERATING INSTRUCTIONS
3.2.1 Summarised operating instructions (daily use)
Routine "pre-start" checks: 1 Check oil level (refer to fig. 9). 2 Check coolant level. 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 MASTERSWITCH is installed, this operates
automatically. 4 Switch on battery switch (when installed). 5 Fuel valve: open.
Starting:
Push the start button to initiate the full automatic
starting procedure. You can monitor the procedure on
the display.
In operation checks: 1 Check for abnormal noise or vibration 2 Check the voltage
3 Power source selector switch (off/shore
power/generator power). Switch to power source generator. If a MASTERSWITCH is installed, this operates automatically.
4 Before loading the generating set up 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 (i.e. 30% of 3 kW is approx. 1000W) and let it run for
approx. 5 minutes. 2 Press the STOP button. 3 Switch to another 230V power source, if available. If a
Masterswitch is installed, this is done automatically.
3.2.2 Extended operating instructions
Check when starting the first time or after a longer period of rest: 1 If there is any damage caused by transport or
installation. 2 Check if installation conforms to the installation
instructions. 3 Ensure the generating set is free to turn without
obstruction. 4 Check all hoses and hose connections for leaks. 5 Check all cables and cable end terminal connections. 6 Check the engine and generator mounting bolts.
Routine "pre-start" checks: 1 Check engine oil level.
The generator switches off in the event of insufficient
oil-pressure. Even when the oil level is too low the oil
pressure can be high enough. Do not run the
generator with the oil below the lowest mark in the,
because a smaller volume of oil will become
contaminated considerably quicker than a larger
volume. Therefore we recommend daily oil-checks.
Check oil level prior to starting the engine or at least 5
minutes after the engine has stopped. 2 Check coolant level 3 Check for leaks. 4 If no MASTERSWITCH is used: Switch main Power
Source Selector switch to "OFF" or switch off all
devices. 5 Switch on the battery switch.
Page 17
OPERATION
EN / W-SC3 Mobile / January 2011 17
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)
The W-SC3 can even be started with an almost discharged battery using the cylinder compression release handle. The engine can then be rotated easily ("turned over") as the valves are opened i.e. in the decompression position. You can also use the decompression handle to readjust the valve clearance and to fill the cooling system with anti freeze for conservation in winter time.
A restart protection prevents starting the engine when it is already running, which could cause damage.
Checks once the generator is in operation: 1 Check for abnormal noise or vibration. 2 Check the voltage. 3 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 generating set up to maximum, have it run warm. The first 50 hours of running the continuous load should be restricted to 70 % of maxi­mum load. Running for long periods at no load or light load in the first 50 hours can cause cylinder glazing and high oil consumption.
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.
The generator should therefore only be loaded at the maximum rated power for short periods (2-3 hours) only!
The high peak current is meant for the ability to start electrical devices that need a high current for starting especially electric motors and compressors (from a still stand state). In order to prolong the generating set’s life expectance, the nominal electrical demand on the system should be about 80% or the rated generating set’s maximum load. Please note this when switching on your electrical devices!
Nevertheless, the W-SC3 is designed so as not to overheat, even under extreme conditions.
Do not run the generator for very long periods at no load or 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
Stopping the generating set:
1 Avoid stopping of the generator abruptly after a long
period of operation at high load! Doing so, you avoid
unnecessary thermal load to your generating set!
Act as follows:
Prior to switching off the generating set, decrease the
generator load (i.e. turn off most electrical users) and
let the generator run at low load for approx. 5 minutes
to allow the engine to get properly cool. If the
generator is operating 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,
compressors (in refrigerators or air conditioners etc.).
Figure 10: Decompression handle
Page 18
OPERATION
18 January 2011 / W-SC3 Mobile / EN
2 Press the STOP button.
3 Switch to an other 230V power source, if available. If
a Masterswitch is installed, this is done automatically.
If the engine is not running and ‘failure’ and ‘charging’ LED is blinking, reset by stop button, otherwise it will drain the start battery
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. The insulation resistance to earth of all windings should be in excess of 1.0 MOhm. Should the insulation resistance be less than this value, drying out the generator windings is essential. Drying out can be carried out by direct warm air from a fan heater or similar apparatus into the generator air inlets or outlets. All bearings are greased for life and not regreasable.
4.2 ENGINE
4.2.1 Preliminary instructions
All regular maintenance can be carried out when the en­closure is open. For repairs we recommend to take out the generating set to a workshop. The enclosure can be completely removed by taking out the bolts form the aluminium bars below the bottom of the capsule. When oil and dirt have gathered in the enclosure measures have to be taken to avoid spilling oil and polluting the environment.
The first service on the engine should be carried out after 50 hours of its life. This also applies after a major over­haul. In the first 25 hours the engine should receive special attention: Long periods of light or no load running in the first 25 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. Push the start button activating the electric system and activating the fuel pump. When more time is needed to bleed, push “start” and hold on the local control panel (so not on the remote panel). Hold as long as necessary to bleed the system.
Figure 11: Self bleeding fuel lines
4.2.3 Valve clearance
Tightening torques, refer to § 5.4.2. When the engine is in cold condition both valves should have a clearance between 0.14 and 0.18 mm. The adjustment has to be done at T.D.C. of the compression stroke. Using a pocket light one can check the position of the flywheel (refer to picture 12). By using the decompression handle one can crank the engine easily with a screwdriver to put the marks in line. Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation. If the rocker arms move the piston is on the T.D.C. of the intake or exhaust stroke. In such a case turn the crankshaft 360° in the direction of engine rotation again. The piston is now at T.D.C. of the compression stroke. After readjustment one should crank the engine for 20 rotations and check the valves again.
Page 19
MAINTENANCE
EN / W-SC3 Mobile / January 2011 19
Figure 12: Valve clearance
4.2.4 Replacing fuel filter
Filter change depends on contamination of the fuel, but should be done however, at least every 1000 running hours. Before changing the filter, clamp off the supply line. Remove the hoses from filter and attach them on the new filter again. The arrow on the filter housing indicates the direction of the flow. A clogged filter results in a lack of output of the generating set.
4.2.5 Cleaning oil strainer
The oil strainer is behind a plug on the bottom of the engine (refer to figure 2, no. 35). In the strainer is a magnet to catch the metal parts which are in the lubricating oil. Once per 1000 hours or when the oil is contaminated one can clean the strainer by washing it with petrol or a solvent. A green rubber plug in the capsule gives access to the strainer. Before taking out the plug one should sump the oil. Use tissues to avoid spilling oil in the capsule.
4.3 REGULAR MAINTENANCE
CHECK DAILY:
Oil level (see fig. 13) Take care the oil level is never below the mark.
Coolant level
Hoses for loose connections or deterioration.
1 Filling cap 2 Minimum oil level 3 Maximum oil level
Figure 13
AFTER FIRST 50 HOURS:
Change oil. Have the engine run until it is on temperature and stop it. Drain oil by the sump pump into a suitable retainer and fill up with fresh oil. Start the engine again and have it run for 5 minutes. Stop the engine again and pause for a few minutes to let the oil gather in the crankcase. Check the level again and add oil when necessary.
Check and tighten nuts, bolts, and unions, paying particular attention to the fuel system.
Check the valve clearance.
Observe the exhaust at the normal full load. The
exhaust must be free from soot. Do not allow the engine to run with a dirty exhaust without investigating the cause as this may result in an expensive breakdown.
EVERY 150 HOURS:
Change oil.
Check the battery acid level.
Check battery terminals for corrosion
Page 20
MAINTENANCE
20 January 2011 / W-SC3 Mobile / EN
EVERY 300 HOURS:
Check and if necessary replace the impeller of the water pump.
Check valve clearance.
Replace the fuel filter
Replacement depends on the condition of the fuel. We recommend replacement every 300 hours. Isolate the fuel supply and change the element.
EVERY 500 HOURS:
Replace the impeller of the water pump.
EVERY 1000 HOURS:
Clean the oil strainer.
Check and clean radiator with compressed air.
EVERY 2000 HOURS:
Check lubricating oil pressure
Clean and check or replace fuel injector nozzles
and check injection pressure.
Check the air filter element: The air is taken in via the cover on the alternator. Below this cover is a spongy material which filters the air and holds some electrical components which are cooled by the inlet air. This filter does not require regular maintenance. Only in very dusty circumstances this filter should be cleaned. The spongy material can be washed in solvent or replaced.
Check and clean radiator with compressed air.
When the generator set runs less than 100 hours a year the oil should be changed yearly
4.3.1 Maintenance schedule
Check oil level daily
Check the level of the cooling liquid daily
Change oil; check and replace oil filter; check and readjust
valve clearance after first 50 hours
Change oil 150 hours
Check impeller water pump 300 hours
Retighten cylinderhead bolts and readjust valve clearance 300 hours
Replace fuel filter 300 hours
Replace impeller water pump 500 hours
Clean radiator with compressed air 1000 hours
Retighten cylinderhead bolts , adjust valve clearance 1000 hours
Clean the oil strainer 1000 hours
Check injector and injection pressure 2000 hours
Check inlet air filter 2000 hours
4.3.2 Putting 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 preservation diesel fuel. Start the engine and run the engine warm.
3 Drain the hot engine oil and refill with preservation oil.
4 The coolant can stay in the alternator and radiator.
5 Disconnect the battery and store it in a place free of
frost and dry and charge it regularly.
6 Close inlet- and outlet openings with tape.
7 Protect the generating set against the influences of
bad weather conditions.
This method of preservation will be sufficient for 6 months. Repeat steps 2, 3, and 4, every 6 months. Change oil before using the engine again.
Page 21
TROUBLE SHOOTING
EN / W-SC3 Mobile / January 2011 21
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
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. If in doubt, measure directly on the alternator terminals with an independent instrument.
This should only be carried out by an experienced electrician. Check if the engine is running correctly at 3000 (50 Hz) RPM according to its settings and does as well under load. A RPM drop of 5% at full load is acceptable. There-fore a no load setting should be at 3150 RPM = 52.5 Hz or 3750 RPM = 62.5 Hz. Under no circumstances should the RPM under full load be below 2940 RPM = 49 Hz or 3540 = 59 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.
5.1.2 Trouble shooting table
PROBLEM CAUSE SOLUTION
No output (Voltage) at all
Circuit breaker "off" or faulty fuse
Check switches and fuses and measure directly on the alternator to exclude external causes.
Low engine RPM.
Check the engine RPM and adjust (refer to special procedures).
Loss of residual magnetism.
Check the residual magnetism and flash the alternator (refer to special procedures).
Capacitor loose or broken.
Check by independent excitation if the problem is in the capacitor or in the windings.
Rotor diodes broken.
Check the diodes in the rotor (refer to special procedures) The W-SC3 has two diodes in the rotor. It happens very rarely that both are broken. When only one diode is broken the voltage will be low but will not varnish completely.
Generator output voltage too low when no load is on it (less than 210V).
No load at all or very low load.
Switch on a load and check voltage.
Engine is not reaching the rated RPM.
Refer to special procedures to readjust RPM.
Defective capacitor.
Check capacitor and replace if necessary (refer to special procedures).
Defective diode (one of the two)
Check the diodes in the rotor and replace (refer to special procedures).
Generator output voltage too low under load (less than 210V). In no load condition it is ok
Generator is overloaded.
Switch off a load; (part off) consumers.
Engine is not reaching the rated RPM.
Refer to engine RPM problems
Defective capacitor
Check capacitor and replace if necessary (refer to special procedures).
Generator voltage too high, (more than 245V)
Engine is running too fast (RPM too high).
Check engine speed and adjust (refer to special (more than 245V).procedures).
Over-energising due to defective capacitors
Check capacitor specification and replace capacitors if necessary.
Presence of a strong capacitive load (leading power factor)
Compensate for this capacity and seek for experts advice.
Page 22
TROUBLE SHOOTING
22 January 2011 / W-SC3 Mobile / EN
PROBLEM CAUSE SOLUTION
Generator voltage fluctuates.
Disturbances on the electrical system/ user side.
Check if electrical load is fluctuating
Engine runs irregularly.
When engine runs irregularly refer to section: "Engine runs irregularly".
Generator is not able to start an electric motor
If the generator is unable to supply enough power to start an electric motor (230V), this is usually because this motor draws too much current during starting
Check the electric motor’s current draw required for starting. This should not exceed 70% of the rated generator output current. This could be remedied by providing stronger capacitors to the motor or using a "soft-start". Inquire at your nearest Whisper Power dealer or directly at the manufacturer, Whisper Power in the Netherlands.
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. When there is no obvious cause one can adjust the RPM (refer to special procedures). The Digital Diesel Control system will help to indicate failures and display causes.
When the engine is not cranking well starting problems almost always originate from battery problems or poor battery cable connections. When the engine is cranking, well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes.
A failure code is displayed when a hardware failure at the generator is detected.
failure code problem
COMMUNICATION Communication error between the
panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage EXHAUST TEMP Exhaust temperature is too high WATER TEMP Coolant temperature is too high OIL PRESSURE Oil pressure failure LOW VOLTAGE Generator AC output voltage is too
low HIGH CURRENT generator is in overload FREQUENCY output frequency of the generator is
too low
5.2.2 Trouble shooting table
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 in the connection between battery and starter
The problem must be an electric malfunction.
Starter battery switched "OFF".
Check position of the battery switch and switch "ON".
Starter battery voltage insufficient (battery too weak).
Check battery voltage. Recharge the battery. Inspect battery terminals and cables for a good electrical connection (inspect against corrosion, tattered wires, etc.) During the normal starting process, the battery voltage drops to 11V (with a fully charged battery). If the voltage does not drop during starting, the electrical connection is faulty. If the battery voltage drops lower than 11V, then the battery has been discharged too deep.
Starter broken
Repair the starter motor
To thick engine lubricating oil.
Change oil for a lower viscosity.
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TROUBLE SHOOTING
EN / W-SC3 Mobile / January 2011 23
PROBLEM CAUSE SOLUTION
Starter is turning engine smoothly, but engine fails to start
Out of fuel or faulty fuel, water in the fuel.
Fill up with fuel or replace with better quality.
Fuel inlet solenoid valve is not opening.
Check wire connections and circuitry to solenoid. (Refer to DC wiring diagram)
Fuel lift pump is not working.
Fuel filter is blocked.
Air in fuel lines.
Check fuel filter and fuel lift pump: clean or replace if necessary. Bleed air from fuel system (refer to maintenance section).
Low compression because of dirty valves.
Clean valves. Take off the injection bent and inspect the outlet port. When little rust in the port clean the valve by taking off the valve spring and rotate until rust is removed.
Wrong valve clearance.
Adjust valve clearance,
Blocked injector.
Have the injector tested and cleaned if necessary.
Engine runs irregularly.
Unsuitable contaminated fuel
Lack of fuel.
Fill up with fuel or replace by better quality.
Choked fuel filter.
Check fuel filter and fuel lift pump: clean or replace if necessary.
Faulty fuel lift pump.
Check and repair
Choked air filter.
Lack of air.
Check the air intake
Choked exhaust system, exhaust chocked rubber exhaust hose kinked.
Check the exhaust hose
Air in the fuel pipes
Bleed air from fuel system (refer to 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 blocked,
Check exhaust system. (manifold and mufflers inside)
Generator overloaded by over- energising.
Reduce the electrical load (switch off some consumers).
Generator over energised.
Check that the proper capacitor type is installed and that it is connected correctly.
Defective generator (windings, bearings or other)
Generator must be sent to manufacturer for repair of damaged bearing or winding.
Damaged engine
Repair by Whisper Power service
Engine does not stop on command
Loss of control
Faulty Digital Diesel Control unit. Stop the engine manually by the stop handle. Check wire connections to stop solenoid. Check solenoid valve function. Replace if necessary.
Engine exhaust smokes
Faint blue smoke - generally the result of light load
Increase load.
Heavy blue smoke - caused by lubricating oil: Overfull oil sump or worn cylinder bore, stuck broken or worn rings.
Check the oil level. Check the compression.
Black smoke –incomplete combustion caused by: Overload, choked air filter, inlet temperature too high, unsuitable fuel or water in fuel.
Check the fuel . Check for overload.
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TROUBLE SHOOTING
24 January 2011 / W-SC3 Mobile / EN
PROBLEM CAUSE SOLUTION
Engine starts, but stops after 10 up to 30 seconds
Protection system stops the engine; this can be caused by oil pressure failure. Overload, loose wire or faulty alarm switch. Digital Diesel Control will help to indicate failure.
Refer to paragraph 2.5.5. and 3.2.2 for information on the alarm system. Bypassing the switches can help to confirm the failure.
Engine stops by itself
Overload or short circuit.
Switch off the consumers and test for short circuit.
Lack of fuel.
Check fuel supply system: fuel lines, pump, filter, valves, tank level, etc.
Oil pressure low. (oil pressure switch tripped).
Check oil level. Check engine’s oil pressure and have it repaired by Whisper Power.
Excessive heat in cooling system (thermo-switch tripped).
Lack of cooling water (exhaust switch tripped).
Impeller broken.
Cooling water blocked.
Water strainer blocked.
Air or water in the fuel.
Blocked air or fuel filter.
Check cooling liquid level expansion tank: water pump, impeller: coolant flow. Check if radiator fan works properly. Air in system can block circulation. Almost all problems of over heating are caused by faulty installation: bents in the routing of cooling pipes that captures air bubbles (air locks) or hot air circulating back into the radiator. Refer to installation manual.
Loss of compression by wear out or damage.
Repair by Whisper Power service.
Overload or short circuit.
Switch off the consumers and test for short circuit.
Sooty, black exhaust.
Generator is being overloaded. Digital Diesel Control will indicate “overload”.
Check electrical load and switch off some consumers
Insufficient intake air.
Choked air filter.
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.
Increase load and have the engine run for a few hours
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. When any doubt, measure the power directly with an appropriate instrument.
Overfull oil sump.
Bring the oil to the correct level
Choked fuel filter.
Replace the fuel filter.
Choked air filter.
Check air inlet openings; clean air filter.
Faulty fuel pump
Replace
Exhaust blocked.
Check the exhaust system.
Injector blocked.
Have the injector checked.
Loss of compression, sticking.
Have the compression measured.
damaged piston ring.
Clean or replace the rings.
Wear out of cylinder.
Have the compression measured and have the engine overhauled.
Over-temperature
Overload.
Take away the overload.
Low oil level.
Fill up with oil.
Water inlet system blocked.
Check the cooling system thoroughly.
Broken impeller.
Radiator choked
Clean radiator
Hot air circulating into radiator.
Check and refer to installation manual
Engine stops very slowly
Engine should stop within 20 seconds after pushing STOP button
Stop solenoid is faulty an engine is stopped by shut off valve
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TROUBLE SHOOTING
EN / W-SC3 Mobile / January 2011 25
5.2.3 Warnings
Generator must be shut off immediately if:
• Motor RPM suddenly rises or drops.
• Unusual noise comes from generating set.
• Exhaust gases suddenly colour dark.
• Engine failure warning light is on
5.2.4 Service address
If you cannot correct a problem with the aid of the mal­function table, contact your Whisper Power Service Centre or Whisper Power in the Netherlands for an extended service list, tel: INT +31-20-3422100.
5.3 SPECIAL PROCEDURES ALTERNATOR
5.3.1 Residual voltage check / excitation procedure
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. This can be solved by charging the capacitor ("flashing") independently with a small 9 Volt battery. This can be done while the engine is stationary and the wiring is connected.
If the generating set battery is used for flashing one must take care. A short circuit can cause heavy sparking, fire and injuries
When flashing does not bring back voltage, the capacitor(s) should be renewed. When this does not help, the rotating rectifier diodes should be tested and a winding resistant test should be executed.
5.3.2 Testing rotary rectifier diodes
The diodes in the rotor can be checked with a multimeter. When both diodes are faulty the alternator will not generate any voltage. When only one diode is faulty the
alternator will generate about half the normal voltage. The flexible lead connected to the diode 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 direction. A faulty diode will give a full deflection reading in both directions with the test meter on the 10,000 ohms scale, or an infinity reading in both directions. The problem can also be in a faulty surge suppressor which is a metal-oxide varistor connected across the diodes, or the ESD capacitor. Replace the diodes, the suppressors and the capacitors.
5.3.3 Winding resistant values
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. Resistance values should be within 10% of the values given in the table below:
Resistance 50Hz
Resistance both main stator windings
in series
1.2 Ohm
Resistance both rotor windings
2.1 Ohm
Resistance battery charger winding
0.15 Ohm
Resistance exciter stator winding
2.4 Ohm
1 Varistor (420V); 2 EMC capacitors (4,7nF - 630V);
3 Diodes (25A - 1200V). Fig15
Figure 14
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TROUBLE SHOOTING
26 January 2011 / W-SC3 Mobile / EN
5.3.4 Meggering
One can try to measure resistance between the housing and the windings with a multimeter which should read infinity. When readings are infinity but a fault is suspected one can do a high voltage resistance test (MEGGERING) This procedure should be carried out by an expert
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 nominal 3000 (50 Hz) RPM. A RPM drop of 5% at full load is acceptable. Therefore a no load setting should be at ± 3150 RPM = 52.5 Hz. Under no circumstances should the RPM be under full load below 2940 RPM = 49 Hz. When no cause can be found for a wrong speed, the setting can be adjusted: It is very important to identify the correct setting assembly (refer to fig. 16).The screw is to be locked in position with the lock-nut.
5.4.2 Tightening torques
Valve clearance, refer to Maintenance, §4.2.3. Cylinder head screws M10x1,5: 51,9 to 56,8 Nm; 5,3 to 5,8 kgf-m. Rocker arm bracket mounting: M8 x 1,25: 23 to 27,4 Nm; 2,4 to 2,8 kgf-m.
5.4.3 Disassembling instructions
It could be necessary for repair or checks to disassemble the generating set. One can take off the white cover easily for regular maintenance and inspection. For further repair or inspection one can take off the upper green part as well. Following instructions will help:
1 When the generating set has to be taken out of its
enclosure we strongly advise not to do this in a narrow space on a vehicle, but to take out the complete set and take it to a workshop.
2 To take out the generator all connections have to be
taken off. The outgoing hose on the oil cooler is most difficult to get to, but can be reached from above by taking off the cover which is on the cylinder head of the engine. By taking out 4 screws from the aluminium bars the generating set will come loose from the capsule.
3 The easiest way to get the generator out of its capsule
is by lifting the set using the lifting eye and removing the capsule downwards.
4 The cooler elements are welded to the alternator
housing with silver and cannot be disassembled. How-ever one can take off the complete alternator housing.
5 Before the alternator can be taken off one has to take
out the fitting to the oil cooler to be able to take off the aluminium housing. All cables and wiring have to be loosened first.
6 The rotor can be taken off by removing the bolt which
goes through the shaft (normal clockwise threaded). The end of the shaft is specially threaded to push off the rotor from the conic stub shaft, which is on the flywheel, using a 6-mm rod of 165-mm length and a M10 bolt.
7 Reassembling the generating set one should take
care of alignment, cleaning the surfaces between engine and alternator and tighten the bolts crosswise and gradually.
8 Use Loctite 577 to seal the fittings, which should first
be cleaned and made free of oil and grease. Test the generating set first outside its capsule and check very carefully for leakages before putting it back in its enclosure.
A disassembly, reassembly instruction is available on our website on the internet: www.whisperpower.eu.
Fig 16: RPM setting assembly
Page 27
SPARE PARTS LIST
EN / W-SC3 Mobile / January 2011 27
6 SPARE PARTS LIST
A parts manual in English is available as an option number: 40200180(***). A work shop manual in English is available as an option number: 40200170(***).
We recommend the following spares for service and maintenance.
Kit A: parts for regular maintenance parts marked(*) article no 40201260
Kit B: parts for maintenance + spare parts: all parts marked (*)+(**) article no 40201261
Kit C: parts for "world travellers" all parts marked (*)+(**)+(***) article no 40201262
ARTICLE NO DESCRIPTION
40209030 Fuel filter (*)
50201062 Fuel lift pump (**)
50201051 Fuel valve solenoid (**)
50221609 Banjo eye fuel valve (**)
50201034 Copper washer connection bolt, M10 x 16 (**)
50201035 Copper washer, M12 x 18 (**)
50202048 Stop solenoid (***)
40201240 Water pump complete type K (***) (refer to fig. 17)
40209011 Impeller + gasket (3,4,5) (*)
50209021 Cover water pump (**) (2)
50209018 Bolts cover (**) (1)
40201251 Pump repair kit A consisting of:
- Shaft (13)
- Bearings (2 pcs.) (10)
- O-ring (9)
- Seals (2 pcs.) (8)
- Clips (1 set) (11, 12)
40209010 Pump repair kit B (**)(same as repair kit A excluding the shaft)
-- Capacitor 40 micro-farad (**)
50209132 Measuring coil (***)
50201290 Rotary diodes (2 pcs) (including varistors and capacitors (**)
50201085 Alternator bearing including O-ring (**)
40209140 Local control panel on the engine (***)
50212175 Fuses 30 Amps (*)
50212170 Fuses 10 Amps (*)
50201067 Wiring loom complete DDC (***)
40209102 Digital Diesel Remote Control panel (***)
50209136 Cable remote control 10 mtr, including connectors
50202034 Gasket valve cover (**)
50202030 Cylinder head gasket kit
50202036 Overhaul gasket kit + seal kit (***)
50202040 Glow plug (**)
50202050 Nozzle injector (**)
50202160 Fuel pump (high pressure) complete (***)
50209051 Silicone O-ring sound shield cover (**)
More extensive parts list on the internet: WHISPERPOWER.EU (fast moving parts)
Page 28
NOTES
28 January 2011 / W-SC3 Mobile / EN
Spare parts water pump type K, article no 50201250:
No description article no
1 screw cover, 6x 50209018
2 cover water pump 1x 50209021
3 screw impeller, 1x refer to impeller
4 Impeller (1x), including screw (3) 50209013
5 Gasket, 1x 50209012
6 Pump housing, 1x 50201013
7 Hose connector, 2x, 12,5 MM x 3/8” 50221001
8 Seal, 2x 50209015
9 O-ring, 1x 50209017
10 Bearing, 2x 50209014
11 Clip, 2x 50209019
12 Clip, 1x 50209016
13 Impeller kit: impeller + gasket + screw 40209011
Fig 18: Water pump type K
Page 29
NOTES
EN / W-SC3 Mobile / January 2011 29
MAINTENANCE LOG
first service after 50 hours: hour counter: remarks:
next service (every 150 hours): hour counter: remarks:
Page 30
NOTES
30 January 2011 / W-SC3 Mobile / EN
NOTES
Page 31
NOTES
EN / W-SC3 Mobile / January 2011 31
NOTES
Page 32
Kelvinlaan 82, 9207 JB Drachten, Netherlands
Tel : + 31-512-571550 / Fax : + 31-512-571599
www.whisperpower.eu / info@whisperpower.nl
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