Whisper Power W-SQ 6, W-SQ 8, W-SQ 16, W-SQ 12 Installation Manual

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INSTALLATION MANUAL

W-SQ 6 / 8 / 12 / 16

- 1500 RPM -

Mobile diesel generating set 230V / 50Hz

Digital Diesel Control

WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten

Netherlands Tel.: +31-512-571550 Fax: +31-512-571599 www.whisperpower.com

V1.1 December 2016

Art.nr. 40200241

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CONTENTS

2 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

CONTENTS

1 INTRODUCTION .............................................................................................................................................................. 3

1.1 General .............................................................................................................................................................. 3

1.2 Generating sets for vehicles ............................................................................................................................... 3

1.2.1 Marine and mobile generators ........................................................................................................... 3

1.2.2 Why two radiators .............................................................................................................................. 4

1.2.3 Why the alternator should be liquid-cooled ........................................................................................ 4

2 INSTALLATION ............................................................................................................................................................... 5

2.1 General .............................................................................................................................................................. 5

2.2 Location .............................................................................................................................................................. 5

2.3 Instructions for optimal sound and vibration insulation ....................................................................................... 6

2.3.1 Further recommendations ................................................................................................................. 6

2.4 Ventilation........................................................................................................................................................... 6

2.4.1 General .............................................................................................................................................. 6

2.4.2 Air strainer element ........................................................................................................................... 7

2.5 Connections ....................................................................................................................................................... 7

2.5.1 Fuel supply ...................................................................................................................................... 12

2.5.2 Radiator cooling............................................................................................................................... 14

2.5.3 Dry exhaust system ......................................................................................................................... 18

2.5.4 Electrical installation (12 Volt) ......................................................................................................... 20

2.5.5 AC power system (230 Volt) ............................................................................................................ 23

3 INSTALLATION SPECIFICATIONS .............................................................................................................................. 24

3.1 General ............................................................................................................................................................ 24

3.2 Commission table ............................................................................................................................................. 24

3.3 Technical data ................................ ................................ .................................................................................. 25

3.4 Installation materials ......................................................................................................................................... 26

4 DIAGRAMS & DRAWINGS ........................................................................................................................................... 33

4.1 Layout generator control for W-SQ6, 8 and 12 with 230VAC fan ..................................................................... 33

4.2 Layout generator control for W–SQ6 with 12VDC fan ...................................................................................... 34

4.3 Layout generator control for W-SQ6 with 24VDC fan ....................................................................................... 35

4.4 Layout generator control for W-SQ16 with 230VAC fan ................................................................................... 36

4.5 Wiring colours W-SQ6, 8 and 12 ...................................................................................................................... 37

4.6 Wiring colours W-SQ16 .................................................................................................................................... 38

4.7 AC wiring diagram 230V / 50Hz ....................................................................................................................... 39

4.8 Electrical diagram radiator fan control 230VAC ................................................................................................ 40

4.9 Electrical diagram radiator fan control 12 / 24 VDC .......................................................................................... 41

4.10 Wiring diagram electronic governor (Standard for W-SQ6, 8 and 12) .............................................................. 42

4.11 Remote control panel drawings ........................................................................................................................ 43

4.12 Dimensions W-SQ6 .......................................................................................................................................... 44

4.13 Dimensions W-SQ8 .......................................................................................................................................... 45

4.14 Dimensions W-SQ12 ........................................................................................................................................ 46

4.15 Dimensions W-SQ16 ........................................................................................................................................ 47

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INTRODUCTION

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1 INTRODUCTION

1.1 GENERAL

This installation manual applies to the installation of WhisperPower gensets in vehicles. This manual is valid for the following models:

Part number

Description

41105020

W-SQ6 230V 1500rpm Mobile

41106020

W-SQ8 230V 1500rpm Mobile

41107020

W-SQ12 230V 1500rpm Mobile

41108020

W-SQ16 230V 1500rpm Mobile

For other models see our website: www.whisperpower.com.

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.

WARNING! Before working (installation) on the system read the section safety instructions in the user’s manual.

1.2 GENERATING SETS FOR VEHICLES

1.2.1 Marine and mobile generators

WhisperPower generators originate from the marine sector. But there are also specially designed Whispers available for mobile applications, suitable for supplying power on board of vehicles to use professional apparatus and equipment, strong lightning and air conditioning etc. The cooling system and exhaust system on vehicles is completely different from standard marine systems. On vehicles the engine and alternator are individually cooled by radiator with an electric (12V/24V or 230V) driven fan. The radiators can be fitted below, on top or in the side of the vehicle.

The exhaust is of the dry type and includes a stainless flexible bellow and high quality mufflers.

Never use rubber exhaust hose, nor plastic exhaust parts in a dry exhaust system as applied on vehicles, unless indicated otherwise.

Figure 1: Side-mounted radiator

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INTRODUCTION

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Figure 2: Bottom-mounted radiator

Figure 3: Top-mounted radiator

1.2.2 Why two radiators

The optimum engine operating temperature is between 87° and 92° Celsius. The radiator reduces the temperature of the cooling liquid by only 5°C to 12°C. The returning

“cold” coolant therefore has a minimum temperature of

approx. 75° Celsius. The alternator should be kept as cool as possible. In practice an alternator starts getting less efficient above 40° Celsius. It is hardly possible to cool down the coolant of the alternator below 40° by using a radiator. When a vehicle is in the sun on a parking place the ambient temperature itself could be 40° Celsius. Because of the divergence in the working temperature of engine and alternator it will be clear that it is not possible to combine the cooling of the engine and alternator in one radiator system. Furthermore it will be clear that it is very difficult to cool an alternator optimally with the aid of a radiator in conditions with high ambient temperatures.

1.2.3 Why the alternator should be liquidcooled

For normal industrial use alternators are cooled by air. This requires a flow of air through the alternator of many m³ per minute. With the air, the noise comes out into the open. Generators on vehicles can only made silent by full enclosure in a sound shield canopy. The only opening in the canopy is the inlet for combustion air. For that reason the alternator is liquid-cooled. Although cooling the alternator by circulating coolant through a radiator is not ideal; it is much better than by air. Therefore air-cooled alternators are rarely used in vehicles.

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INSTALLATION

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2 INSTALLATION

Figure 4: Schematic installation diagram

2.1 GENERAL

To ensure reliability and durability of the equipment, it is very important that the installation is carried out with the utmost care and attention. To avoid problems, such as temperature problems, noise levels, vibration, etc. the instructions set out in this manual must be followed and all installation work must be carried out professionally.

2.2 LOCATION

When looking for a proper place for a generator in a vehicle all relevant aspects have to be taken into account

 Accessibility  Solid foundation  Space to mount the radiators (Refer to par. 2.5.2)  Space to mount the exhaust (Refer to par. 2.5.3)  A way to fit the fuel lines

Since WhisperPower generating sets have extremely compact dimensions, they can be installed in tight locations. Please consider that even almost maintenancefree machinery must still remain accessible. When selecting the location area in which to mount the generating set, make sure there is sufficient room to carry out any maintenance work. The unit must be easily accessible on the service side and on the distribution side to have access to the V-belt. All models can be serviced from one side. Oil filling can be done on the service side and on the top (except for WSQ16 that has the oil filler cap only on top). Cooling liquid can be filled via the expansion tanks. The top of the engine (rocker cover) has to be accessible for adjustment of the valve clearance.

Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level is checked regularly.

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2.3 INSTRUCTIONS FOR OPTIMAL SOUND AND VIBRATION INSULATION

Position the generating set as low as possible in the vehicle. The generating set is secured to the base frame by means of flexible engine mountings. This frame is mounted in the vehicle with additional vibration dampers. When it is possible to mount the unit directly on the chassis of the vehicle this has advantages in preventing vibrations by resonance.

2.3.1 Further recommendations

WhisperPower generating sets are standard equipped with a sound cover. This sound cover has been designed to give effective sound insulation. For optimum sound and vibration dampening, the following factors should be considered.

1 Most important is the structure on which the generator

is placed to be stiff. Directly below the rubber mountings the structure should be supported vertically to the chassis of the vehicle.

2 In larger vehicles a separate and insulated space for

the generator will help to damp the noise even further.

3 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

4 Sound dampening is extremely poor if the generating

set is mounted on a light weight flimsy surface such as plywood which will only amplify vibrations. If mounting on a thinner surface cannot be avoided, this should be at least be reinforced with stiffening struts or ribbing. If possible, holes should be drilled or cut through the surface to help reduce the resonance. Covering the surrounding walls and floors with a heavy coating plus foam will certainly improve the situation.

5 Never connect the base of the generating set directly

to walls or tanks.

2.4 VENTILATION

2.4.1 General

The generating set normally draws air from the engine compartment. Engine compartment with natural ventilation must have vent openings of adequate size and location to enable the generating set to operate without overheating. To allow an ample supply of air within the temperature limits of the generating set an opening of at least 100 cm² is required. A "sealed" engine compartment must have a good extraction ventilator to maintain reasonable ambient temperatures. High temperature of intake air reduces engine performance and increases engine coolant temperatures. Air temperatures above 40°C reduce the engine power by 2% for each 5°C of rise. To minimise these effects the engine room temperature must not be more than 15ºC above the outside ambient air temperature. Apply a combination of ventilators, blowers and air intake ducting to meet the temperature limit. The air inlet ducts should run to the bottom of the engine compartment to clear fumes from the bilge and to circulate fresh air. Air outlets should be at the top of the engine compartment to remove the hottest air. An engine compartment blower should be used as an extraction ventilator to remove air from the engine room. In cases where it is impossible to meet the above mentioned temperature limit by using engine compartment ventilation, connections are to be made for an air inlet directly to the generator enclosure. With these connections the generating set can be directly connected to an air duct. Air inlets should be louvered, where appropriate, to protect the engine room and to protect the generating set from rain and water spray.

Figure 5: Mounting of the generating set. X = wrong, V = OK

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INSTALLATION

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Figure 6: Mounting of the air strainer element

2.4.2 Air strainer element

Applying a generator in a vehicle, where combustion air is taken in from below the vehicle, there is often much dust, sand and dirt in the air. For these applications WhisperPower prescribes the installation of an air strainer element. This air strainer element is in the standard supply, but not yet mounted as often the best place to mount it will be different in any installation. To install the air strainer element one has to find the best place somewhere on the canopy. Figure 6 shows the recommended place, but the filter can be mounted everywhere, even on the bottom, hanging down. Use sealant or kit between the flange and the surface.

ATTENTION! In any case it is necessary to open a hole for air inlet!

2.5 CONNECTIONS

The generating set comes with all supply lines and output cables (i.e. electric cables, coolant connections, exhaust, fuel lines etc.) already connected to the engine and

generator. The supply lines are fed through the capsule’s

front base. The connections are marked as shown in figures 7 till 10. All electrical connections, cable types and sizes must comply with the appropriate national regulations. Supplied cables are rated for ambient temperatures up to 70°C. If the cables are required to meet higher temperature requirements, they must be run through conduits.

ATTENTION! Before working (installation) on the system read the section safety instructions.

50230006 AIR CLEA N ER + AD APT ER

50230005 ADAPTER

50230003 AIR CLEA N ER

WHEN NOT USING THE FILTER, THIS HOLE SHOULD BE OPENED

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Figure 7: W-SQ6 connections

Coolant generator in

Battery positive (+)

Fuel out Ø8mm

Fuel in Ø8mm

Battery negative (–)

Coolant engine out

Coolant engine in

Coolant generator out

Expansion tank

Exhaust 1½”

AC power output

Remote control

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INSTALLATION

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Figure 8a: W-SQ8 connections

Figure 8b: W-SQ8 connections

Expansion tank Ø8mm

Exhaust 1½”

Remote control

AC power output

Coolant engine out

Coolant generator out

Battery negative (–) 25mm²

Fuel out Ø8mm

Fuel in Ø8mm

Battery positive (+) 25mm²

Coolant generator in

Coolant engine in

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INSTALLATION

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Figure 9a: W-SQ12 connections

Figure 9b: W-SQ12 connections

Coolant engine out

Coolant generator out

Fuel out Ø8mm

Fuel in Ø8mm

Battery negative (–) 25mm²

Battery positive (+) 25mm²

Coolant generator in

Coolant engine in

Expansion tank Ø8mm

Exhaust 1½”

Remote control

AC power output

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INSTALLATION

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Figure 10a: W-SQ16 connections

Figure 10b: W-SQ16 connections

Expansion tank Ø8mm

Exhaust 1½”

Remote control

AC power output

Coolant engine out

Coolant generator out

Coolant generator in

Coolant engine in

Fuel in Ø8mm

Fuel out Ø8mm

Battery positive (+) 35mm²

Battery negative (–) 35mm²

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INSTALLATION

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2.5.1 Fuel supply

1 FUEL TANK

Fuel tanks should be made of appropriate material such as (stainless) steel or plastic. Steel tanks should not be galvanised or painted inside. Condensation can occur in metal tanks when temperature changes. Therefore, water accumulates at the bottom of the tank and provisions should be made for the drainage of this water. The tank will need a filling connection, a return connection and an air ventilation connection which will require protection against water entry. Some official regulations do not allow connection points at the base of the fuel tank; connections are to be made at the top of the tank with internal tubing down to a few cm above the bottom of the tank. Using the existing fuel tank of the car-engine the fitting should be carried out with extra care. Both a supply line and a return line should be installed and go into the tank from the top. Interference of the two systems (car engine and generator engine) should be avoided.

Do NOT connect the fuel lines to the lines of the vehicles engine fuel supply.

Driving the tank empty below the level of the suction pipe of the generator could make it necessary to bleed the fuel system.

2 FUEL LIFT PUMP

The generating set itself is equipped with a fuel lift pump; therefore the tank can be installed at a lower level than the generating set. See figure 12. The maximum suction height is 1 m. The W-SQ16 has a mechanical fuel lift pump that should be primed manually when the first time used. If the pump has to lift the fuel higher than one meter an external fuel lift pump must be installed (Art. No.

50201060). The control board is already prepared to connect an extra fuel pump. When using a second electric fuel supply pump, it is recommended to mount a loose supplied pump close to the tank and mount it in an angle or vertical to prevent air bubbles to block the system. The pump will become quite hot and should be mounted out of touch. (Refer to fig. 13) The pump makes clicking noises and therefore could be mounted on rubber mountings. When the clicking noises of the pump are not acceptable another noiseless pump is available as an option (Art. No.

50202200).

Fig. 11 Fuel supply (fuel tank is above the generating set)

1 Fuel return 2 Fuel supply 3 Prefilter / Water separator (optional) 5 Fuel Tank

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Fig. 12 Fuel supply (fuel tank is below the generating set)

1 Fuel return 2 Fuel supply 3 Prefilter / Water separator (optional) 4 Extra fuel lift pump (optional) 5 Fuel tank

Figure 13: Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle

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INSTALLATION

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3 FUEL PIPES

When the tank is above the generating set (figure 11) we recommend ending the return line on the top of the tank. When the return is on the top - in case of a leakage the return line cannot overflow because of siphoning. One will only need a fuel cock in the fuel supply line. When the tank is below the generating set we recommend ending the return line on the bottom of the tank (A) below the inlet of the supply line.

Both supply and return fuel pipe lines should be appropriate material and 8 mm outer diameter tubing. The quality of the tubing of fuel pipes could be submitted to local regulations depending on the application of the vehicle. The fuel pipes can be plumbed to the flexible hoses which are on the generating set and have a connection to fit to 8 mm pipe. This fuel line fulfils CE standards and is in accordance with ISO 7840 A2. It is important to avoid bends in the pipes, as they could trap air bubbles. The return pipe should never be connected to the suction pipe. The return line should be of 8 mm diameter and go straight back via the top to the bottom of the tank. When the return is too narrow, has too many bends and goes back to the bottom of the fuel tank, the back-pressure could be too high. This results in irregular running of the engine. When the engine runs irregular, one can check if back-pressure is the problem by disconnecting the return line just outside the canopy and draining it in a canister. When the engine runs smooth now, the return piping has to be changed. It could also help to install a second (electrical 12V) fuel lift pump in the supply line to increase the pressure.

4 FUEL FILTERS

A fine fuel filter is installed which requires maintenance. WhisperPower advises to install an extra fuel filter/ water fuel separator near the fuel tank. Before starting your generating set for the first time follow the fuel system bleeding procedure in the user’s manual.

2.5.2 Radiator cooling

2.5.2.1 TopCool radiator system

Where a roof-mounted cooling system is chosen, WhisperPower offers the TopCool system for optimum ease of installation,. This is an integrated system holding two radiators, one radiator for the diesel engine and the other one for cooling the AC alternator. Integrated in the system, the expansion tanks are always positioned at the right altitude. The TopCool can be mounted in two directions as shown below.

Figure 14: TopCool perpendicular to driving direction

Figure 25: TopCool in parallel with driving direction

Depending on the cooling requirements of the various generator models, the following systems are recommended:

Part number

Description

40230626

TopCool for W-SQ6

40230628

TopCool for W-SQ8

40230629

TopCool for W-SQ12

40230630

TopCool for W-SQ16

Detailed installation instructions are provided with these systems.

2.5.2.2 Other radiator cooling systems

1 GENERAL INSTRUCTIONS

The radiators can be mounted below the floor, in the side or on the roof of the vehicle. Wherever the radiators are mounted the well-functioning of the system depends on the circulation of the coolant. Roof mounted radiators bring the most risk for circulation problems, because air trapped in the radiators or a low level of the coolant, will immediately affect the cooling capacity of the radiators. It is recommended to keep the radiators as close as possible to the unit. The piping should be fitted as direct as possible. When the radiators are above the engine, the piping should be fitted below the top of the radiators! (refer to

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figure 16). Bends in the piping, that can trap air bubbles, should be avoided or ventilated (refer to figure 17).

Figure 16: Air traps should be avoided

Figure 17: Ventilating an air trap

Special attention should be paid to the ventilation of the systems. Each installation system is standard supplied with an expansion tank for the coolant, which is also used to release air bubbles and makes it possible to add coolant into the system in an easy way. This expansion tank should be at the highest point of the system and mounted as high as possible.

Most cooling problems originate from air traps blocking the circulation of the engine coolant.

Figure 18: Alternator cooling system: open expansion tank with overflow pillar

For the alternator cooling system we use an open -non pressurised- system. Therefore the 12 mm overflow pillar on the expansion tank should stay open (figure 18). A piece of hose can be used to drain redundant liquid that is thrown out because of the expansion of the liquid in the system. When open the expansion tank can easily release air that is ventilated by the different connections. As the capacity of the alternator cooling system is very small, also the initial filling can be done via the expansion tank. It could be necessary to refill the tank a few times. The pump of the alternator cooling system is self-priming and this makes the system less sensitive for air traps.

For the engine we use a pressurised system. The 12 mm connection on the top is closed. Wherever the radiators are mounted it is necessary to ventilate the exhaust manifold of the engine. The exhaust manifold has a 8 mm connection to ventilate the manifold. There is an 8 mm high pressure and high temperature resistant hose in the delivery to connect the hose connection on the side of the manifold with the expansion tank. (refer to figure 7 till 10).

Initially the engine cooling system can be filled via the cap on the exhaust manifold of the engine. However when the radiator is above the engine one can only fill the system to

Piping should not be fitted above the radiator!

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the level of the manifold. Additional filling has to be done via the expansion tank. For large engine cooling systems with long pipes or for extra reserve there is an extra-large expansion tank with a content of 7 litres and an alarm for low coolant level that can be supplied as an option (refer to figure 19).

Figure 19: 7 litres optional expansion tank with low level alarm

When mounting the radiators it is important to take care that the outgoing connection, which is the connection to the engine inlet, is on the top position (refer to figure 20 detail A) and is connected to the expansion tank. Also when the radiator is mounted flat at the bottom of the vehicle the outgoing connection is connected to the expansion tank This is the best way to have the system release air and to add liquid when necessary.

The expansion tank must be fitted in the outlet of the radiator = the inlet pipe of the engine

Figure 20: Outgoing connection connected to the expansion tank

When both radiators are flat mounted on the roof, the expansion tanks should be mounted a little higher. (refer to figure 21 detail B).

Figure 21: Low profile radiator assembly on the roof

Most cooling problems originate from air traps blocking the circulation of the engine coolant.

It is very important to use good quality heat resistant hose and fittings. Therefore it is strongly advised to use WhisperPower installation kits from WhisperPower.

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2 HOW AND WHERE TO MOUNT THE RADIATORS

The radiator kit includes rubber mountings to prevent vibrations to be transferred to the body of the vehicle (fig.

22). Due to the difference between vehicles general

instructions are not available. One has to find out where the best place for mounting is. For OEM customers WhisperPower can supply a special customised installation kit.

Figure 22. Radiator on rubber mountings

Bottom mounted radiators

When bottom mounted the radiator should not be the lowest point of the vehicle to avoid damage. A free flow of air should be guaranteed. When horizontal mounted, the fan should be on top, which causes a flow of air downwards. Often it is possible to find a place where extra space above the fan helps to create a free flow of air. It is recommended to make a shield below the radiator to catch stones and dirt and operates as a spoiler. The distance between the radiator and the shield should be at least 50 mm. Sometimes it is possible to build the radiators and shield on a sub frame that is mounted below the vehicle as a module.

Measures have to be taken to prevent the hot air circulating and reducing the capacity of the radiators. Refer to figure 23.

Figure 23: Bottom mounted radiators with shield

Figure 24: Making use of the space below the floor to get an optimal flow of air through the radiators

Side mounted radiators

Most effective and easy is to mount the radiator in the side of the vehicle, if possible below the level of the top of the engine. A louvered grid should protect the radiator from rain and objects, but must not block the airflow. The fan should be inwards which causes the air to blow outwards. A disadvantage of having the radiator in the side is possibly more noise of the electric fan and a flow of air that could be felt by people passing by. A free flow of air should be guaranteed. The ventilation connection of the cooling system that goes to the expansion tank, should be in the outgoing coolant flow on top of the radiator.

Figure 25: Side mounted radiator

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Roof mounted radiators

The radiators on the roof is often the best option from the point of view of keeping the noise of the fans away from people and it will give the best result in dissipating the heat. However, often this option conflicts with the possible need to keep the vehicle as low as possible. Another disadvantage is that the piping has to go through the roof which requires provisions to be waterproof. Also negative is that roof mounted radiators are more sensitive for air traps (see figure 16). When having enough space it would be ideal to have the radiators vertically mounted on the roof. Note that the expansion tank should be above the radiator. When having the radiators horizontally mounted on the roof (refer to figure 26) enough space (50 mm) should be between the roof and the radiator fan to have a free flow of air. When the radiators are roof mounted there should be protection against weather conditions. To avoid damage while the vehicle is driving at high speed, the use of a spoiler could be necessary.

Figure 26: Two examples of top mount radiators

3 TWO SPEEDS FAN (OPTIONAL)

To keep the noise as low as possible the fans of the radiators can run at two different speeds. As option a control box is available which can be used to drive the fans with two speeds, depending on the load of the generator. When using 12/24V DC to drive the fans (see chapter 4.9), in normal mode the electric motors of the fans are connected in series and run at low speed. In this mode they almost produce no noise. Only when necessary

- this is controlled by thermostat switches - the fans are

switched in parallel and will blow at full speed.

The same is achieved with 230 V fans with help of a transformer (refer to the connection diagrams in paragraph

4.8).

However, when not strictly necessary, we recommend using the standard fan control instead of the two speeds fan control, in order to keep the system as simple as possible.

2.5.3 Dry exhaust system

1 GENERAL REMARKS

A dry exhaust muffler system should be very effective in silencing the exhaust when applying the right mufflers. However noise could be generated by vibrations in the mufflers and be transferred to the chassis. Tacit factors like the length of specific pipe sections could cause the noise to be amplified. It is very difficult to take these factors into account.

Figure 27: Dry exhaust systems on vehicles

The standard WhisperPower exhaust kit contains the materials to perform a professional installation. In the kit is a stainless steel flexible bellow (hose) to allow for expansion and to prevent vibrations to be transferred. Rubbers are supplied to mount the mufflers flexible. The insulation blanket for the flexible bellow and the resonance muffler are also very effective in damping vibrations. Still it could be that additional measures has to be taken like an extra clamp in a vibrating section of pipe, insulation blankets on other parts of the system and possibly even additional mufflers.

When the exhaust is led through the roof of a vehicle, measures has to be taken to prevent rainwater to enter the system. Special rain caps are available as an option.

Figure 28. Ways to prevent water from getting in

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A negative feature of a dry exhaust system is the heat radiated by its components. Measures are taken to overcome the heat problem: The exhaust bend to bring the exhaust out of the canopy is cooled by water. Insulation blankets are included in the exhaust kit to insulate the flexible bellow and the first muffler. When a dry exhaust has its outlet on the roof, all the pipes inside the vehicle has to be insulated.

The exhaust pipes will be very hot and all accessible pipes and mufflers are dangerous to people when not insulated.

There are companies that are specialised in insulating hot pipes and fancy systems are available to make it good looking. However it is also possible to do it yourself by winding fibreglass or Rockwool around the pipes and seal it with aluminium tape.

2 THE STANDARD DRY EXHAUST SYSTEM

The standard exhaust system contains:

On the generator set:

 An insulated exhaust bend

In the exhaust installation kit:

 A stainless steel shielded flexible bellow.  One resonance muffler  One absorption muffler  Clamps and rubbers to mount the system flexible  Fittings, bends and pipes to make the different

connections

 Blankets for thermal and sound insulation.

The mufflers are high quality industrial mufflers that are much more effective, robust and durable than mufflers made for automotive use.

3 INSTALLATION OF THE EXHAUST

Before determining the location of the generator set one has to consider how to get away with the exhaust. Often one can find space below the vehicle between the chassis to mount the mufflers. The outlet should blow the fumes away from the doors to avoid a nasty smell. When the gasses are in the flow of air blowing from the radiators this will help to avoid the fumes to be noticed. Under no condition the fumes should be sucked into the flow of air into the radiators. In wind still conditions a light smell of exhaust fumes around the vehicle will not be avoidable. To bring the exhaust to the top of the vehicle gives the best results on noise and smell. However, when the pipes go through the vehicle they should be insulated and around the hole in the roof should be a collar to prevent rainwater to leak in. Both mufflers could be on the roof or one of them or both could be below the vehicle. In general it is better to have the mufflers wide apart: the resonance muffler close to the generator and the absorption muffler on the end of the line. A short pipe (30cm) should be on the far end after the absorption muffler. The absorption muffler has no flow direction and could be mounted both ways. The resonance muffler should be mounted according to the indication on the muffler itself.

The resonance muffler should be fitted according to direction of the gas flow indicated.

In the kit are clamps to mount the exhaust pipes to stainless steel bars. These bars should be mounted to the chassis of the vehicle. It is recommend to use rubber mountings whenever possible. However take care that the heat conducted through the brackets will not affect the rubber. Refer to figure 29 how to mount the rubber in a safe way. When any doubt an extra safeguard could be constructed from steel wire or chain.

Figure 29: Mounting bracket in rubber with safeguard

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2.5.4 Electrical installation (12 Volt)

1 DIGITAL DIESEL CONTROL SYSTEM

The electrical control system is standard in 12 Volt with negative earth. Non-earth return is available as an option.

All electrical wiring has been prepared on the generating set to the control panel prior to despatch from the factory. The engine is controlled by a very advanced microprocessor based system: Digital Diesel Control.

The “black box” containing the microprocessor is located

on top of the alternator. A local control panel is on the generating set.

Remote control

A remote control panel also containing a microprocessor is in the delivery. A 15 m intermediate 8-pole communication cable is in the standard supply as well (refer to fig. 30). If necessary an optional longer (up to 30m / 100ft) intermediate cable can be connected if the standard length does not suit the required distance. When a longer distance than 30m / 100ft is required, consult the WhisperPower service department for advice.

Fig. 30: Remote control cable

One can mount the control panel after drilling a hole in the dashboard using the plastic cover. Refer to the dimensional drawings in chapter 4.

More remote control panels (slave panels) can be put in parallel by using the modular connectors on the back of the units. As a slave one can use the same panel offering all functions again. It is also possible to use an old or new type slave panel only to start and stop the generator. Old type remote panels and system panels can be connected by means of the green connector.

When using the factory settings, installation is very simple: just plug the remote cable into the remote and the generator is ready to use. Refer to fig. 31.

Fig. 31: Remote box terminals

Acoustic alarm or warning lamp

One can connect an external max.150 mA relay to generate an acoustic warning or applying a warning lamp etc. Be aware of polarity as some relays has a diode inside and should be connected positive tot positive and negative tot negative as indicated. Refer to fig. 31.

Connection for emergency stop / fire alarm switch

To connect an emergency stop button or to stop the generator automatically in case of a fire alarm, you can use the bypass connection between fastons J7 and J18 on the backside of the local control panel. See fig. 32. To do so, remove this bypass connection and then replace it by an emergency switch or a potential free fire alarm switch with normally closed contacts.

Page 21

INSTALLATION

EN / W-SQ6/8/12/16 for mobile applications / December 2016 21

Fig. 32: Connection for emergency stop / fire alarm switch

Automatic starting and stopping

WhisperPower cannot be held responsible for damage caused by the unattended running generator using the auto-start/stop mode or interval mode.

Using the auto-start/stop (interval) mode the generator can start unexpectedly. When working on the electrical system, the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery.

In the delivery are warning stickers to stick on several parts of the electric installation (transfer switch, distribution box, etc.) to warn for automatic start).

The WhisperPower Digital Diesel Control system offers several options for automatic starting and stopping.

Access to this menu and other menus could be blocked. For de-blocking and setting up this options refer to the APPENDIX of the DDC user’s manual. One of these options is to monitor a second battery (not being the starter battery) to start the generator automatically when the voltage of this battery drops below a certain setting.

Other names for this second battery are “auxiliary battery”, “service battery”, ”users battery” or “consumers battery”. We will refer to this battery as “the second battery”(BAT2).

In some menus the starter battery could be indicated as “the first battery” (BAT1). A sense wire to monitor the second battery should be connected (attention polarity!) to the connector on the

back of the remote panel. Refer to fig. 31. The sense wires must be connected directly on the second battery before a main switch and be protected by a 3 Amps fuse. (Monitoring the generator starter battery does not require an extra sense connection).

Settings

When one want to apply other settings than the factory settings refer to the DDC user’s manual, especially to the APPENDIX.

2 STARTER BATTERY

For starting, the engine requires a 12V starter battery with the following capacity:

Model

Capacity

W-SQ6, 8, 12

80Ah

W-SQ16

100Ah

The generating set can be connected with the main engine battery or have its own battery. We strongly recommend the use of a separate battery for the generating set and to keep the wiring system for the vehicle engine and the domestic DC supply system completely separate and individually connected to separate batteries.

Fig. 33: Starter battery

However, the negative of all the batteries on the vehicle should be interconnected to avoid difference in the voltage level of the earth on different places causing trouble to electronic devices which might be in the system. The above recommendation is not valid for vehicles having the starter battery of the vehicle engine or other auxiliary equipment positive grounded. When this is the case an expert should be consulted. A battery switch may be used to interrupt the positive connection. The starter battery is charged by the alternator on the engine. An additional battery charger will help to keep the battery in good condition when the generating set is not used. A battery charger is not included in the standard supply. A high efficiency battery charging unit can be ordered from WhisperPower which is able to charge both the vehicles’s

Remove bypass between J7 - J18

Normal operation

Alarm / emergency

local control panel

(rear view)

Page 22

INSTALLATION

22 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

main battery and the starter battery. Also a small charger can be used to charge the starter battery only, such as the WBC Handy 20 or 70 included in the battery installation kits listed in 3.4.

3 12V OR 24V DC TO DRIVE THE FAN

When applying 12 or 24 VDC to drive the fan of the radiators the fan should be wired with minimum 4mm² cable according to the wiring diagram. The negative return wire should be of the same diameter. The return current should never be lead over the chassis. The consumption of power by the 12VDC powered fan makes it necessary to install an additional 30 Amps battery charger to prevent the starter battery to be drained. A much larger battery (170Ah at least) is required. The battery charging winding in the generating set is not capable of powering the fan. Neither is the small charger that is included in the battery kit. WhisperPower supplies high quality battery chargers that continuously supply the rated power. Chargers of other suppliers are often rated to other standards and give the rated current (Amps) only for a short period if at all. To avoid the need of an extra heavy battery charger a 230 Volt fan on the radiator is recommended. One should realize that the power for the fan must be decucted from the output power of the generating set.

4 OTHER RECOMMENDATIONS AND WARNINGS

The battery should be secured for poor road conditions and the terminals should be insulated. For extra safety the battery can be enclosed in a wooden, plastic, fiberglas etc. (non metal) box. Even when the earth return system is applied a negative battery cable should be used and the vehicle should not to be used as a conductor. The battery cables are supplied in a standard length of

1.5m, if longer cables are required a larger cross sectional area should be considered to compensate for voltage reduction.

When two batteries are used in series to provide a 24 Volt supply system, never take off 12 Volt (starting) power from one of these batteries. This will result in severe damage to both batteries within a short time.

Disconnect the battery leads if electrical welding is to be carried out, otherwise damage will be caused to the diodes of the alternator.

As explosive hydrogen gases may be discharged during charging, the battery should be located in a well ventilated room. Ensure that the supplied battery cable connectors are properly fitted and never remove during or shortly after charging as sparking can occur, which may ignite the hydrogen gasses.

Page 23

INSTALLATION

EN / W-SQ6/8/12/16 for mobile applications / December 2016 23

2.5.5 AC power system (230 Volt)

The electric power supplied by the generator is of a high voltage and dangerous to people. Before working (installation) on the system read the sections on safety in the users manual.

Realise hat 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.

Generators used on vehicles that are operated in a hazardous environment have often to fulfil special regulations and additional measures have to be taken accordingly.

Be sure that all electrical installations (including all safety systems) comply with all required regulations of the local authorities. All electrical safety/shutdown and circuit breaking systems have to be installed on-board as the generating set itself cannot be equipped with such equipment for every possible variation. The vehicle’s power supply system should be suitable and safe for the AC voltage which is applied and the power that will be generated. Special attention has to be paid on dividing the system in branches which are fused individually. It is absolutely essential that each and every circuit in the electrical system is properly installed by a qualified electrician.

1 FUSE

An output fuse (between the generating set and the electrical installation) should be installed to protect the installed electrical system. The following maximum single phase output current applies:

Model

Maximum single phase output current

W-SQ6

25 Amps

W-SQ8

35 Amps

W-SQ12

52 Amps

W-SQ16

70 Amps

The fuses must be of the slow reacting type. For electrical motors connected to the system, a motor protection switch must be installed

2 GROUNDING

The AC alternator windings are not grounded. The housing of the alternator and all other metal parts are grounded To make a connection between “neutral” and “ground” is necessary as part of a specific insulation failure protection system. It is possible that the electric installation in the vehicle must be protected against insulation failures. Methods of protection are subjected to rules that can be different depending on the use of the vehicle and local standards. Experts in this field should be consulted.

3 CABLE

For the power cable we recommend the use of 3 wire single phase oil resistant cable with a sufficient cross sectional area. One wire for earth is included. For long cables it is recommended to apply cables with a larger cross section (refer to ISO 13297 annex A)

4 TRANSFER SWITCH

A power source selector switch much be installed between the generating set and the vehicle’s electrical supply system. This switch must ensure that all AC consumers can be switched off at once. This switch should also be installed to keep the generating set and shore (grid) power systems separate. Transfer switches - to switch over from a land line to vehicle or from generating set to inverter - should be well designed to switch over all wires including neutral (and not only phases or line) and there should be provisions with the aid of timers to prevent relays from clattering.

WhisperPower recommends the installation of a WhisperSwitch as the power source selector. This works automatically when the generating set is not running the input remains in the land line position and as soon as the generating set is running the WhisperSwitch switches automatically after 10 seconds delay time over to the generating set position.

In all situations the transfer switches between land line, inverter and generator should switch both neutral and L1. Of course this is the case when using a WhisperSwitch.

Page 24

INSTALLATION SPECIFICATIONS

24 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

3 INSTALLATION SPECIFICATIONS

3.1 GENERAL

1 Make a hole for combustion air in the sound shield.

Mount an air inlet filter (if required).

2 Mount the generating set directly, without additional

vibration dampers, on a solid surface. 3 Mount the cooling system for the engine. 4 Mount the cooling system for the alternator. 5 Connect exhaust system. 6 Connect ‘fuel supply line’ to the water separator/ fuel

filter. 7 Connect ‘fuel return line’ to the fuel tank. 8 Connect remote panel (just plug in). 9 Connect the AC cable from the AC box to the power

source selector (or WhisperSwitch). 10 Connect plus and minus from the 12V starter battery

to the battery cables. 11 Connect the power supply of the radiators 12 Install a WhisperPower battery charger. (optional)

3.2 COMMISSION TABLE

1 Check if a hole for combustion air intake is in the

sound shield. Also check if an air inlet filter for

combustion air is necessary and has been installed 2 Check if the cooling system for the engine is properly

installed. Note that air traps must be avoided. 3 Check if the cooling system for the alternator is

properly installed. Note that air traps must be avoided. 4 Check if the exhaust system is properly installed.

Check maximum length of exhaust hose, diameter of

exhaust piping. 5 Check all coolant connections. 6 Check the AC cables and the grounding. 7 Check if an AC breaker is installed before or after the

power source selector. When there is only a circuit

breaker, use it to disconnect the generating set from

the grid.

8 Check all DC connections, check if the battery switch/

circuit breaker is closed.

9 Open the fuel valve. Check if there are no air leaks in

the fuel supply line, and check if the lift of the fuel is less than 1 meter. Check if there is no air in the water

fuel separator. 10 Check if the air intake in the canopy is not blocked. 11 Check the oil level and colour of the oil. Check the

coolant level of both the alternator cooling and the

engine cooling 12 To bleed the fuel system:

 W-SQ6, 8, and 12: push the “Start” button on the

local control (not on the remote panel) and hold at least 5 seconds and as long as necessary to bleed the system.

 W-SQ16: use the manual pump by turning the

cap loose and pumping as long as necessary to bleed the system. See chapter 4.2.2 of the user’s

manual. 13 Start the engine by pushing the start button 14 Check when the generating set is running, the delay

of 5 to 10 seconds in the power source selector transfer.

15 Check voltage and frequency under ‘no load’

conditions.

16 Check voltage and frequency under ‘full load’

conditions.

17 Check if the battery charger of the generating set is

working (max. 14.5 Volt). 18 Close the sound shield and check the noise level. 19 Stop the generating set and check the engine again

for leakages of oil, fuel or coolant.

Installation checklist available on our website: www.whisperpower.com. Commissioning form available on our website: www.whisperpower com.

Page 25

INSTALLATION SPECIFICATIONS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 25

3.3 TECHNICAL DATA

W-SQ6 EN W-SQ8

Model

W-SQ6

W-SQ8

Dimensions (l x w x h)

80.5 x 52.5 x 58.0 cm

90 x 58 x 63 cm

Weight including sound shield

240kg

335 kg

Max. operation angle

25°

Remote panel 15 m cable

Digital Diesel Control System

Battery capacity min.

12V / 60Ah

12V / 70Ah

Fuel consumption

1,5 – 4 l/hr, load dependent

Model fuel pump

Electrical driven 12V

Max lift fuel pump

Cooling

Radiator cooling

Cooling pump

self-priming impeller pump, PTO driven

Model cooling pump

M12

Minimum supply

9-15 l/min

18-22 l/min

Alternator

synchronous brushless, maintenance free, liquid-cooled

Voltage regulation

capacitor (+ optional: AVR )

Output power at 50Hz, power factor cos phi = 1

5.7 kW*

8 kW*

Battery charger (alternator including regulator):

40 Amps

50 Amps

* Note that this value must be reduced by the power to drive the cooling fans of the radiators.

W-SQ12 AND W-SQ16

Model

W-SQ12

W-SQ16

Dimensions (l x w x h)

106 x 58 x 63 cm

116 x 58 x 70 cm

Weight including sound shield

380 kg

440kg

Max. operation angle

25°

Remote panel 15 m cable

Digital Diesel Control System

Battery capacity min.

12V / 70Ah

12V / 120Ah

Fuel consumption

1,5 – 4 l/hr, load dependent

Model fuel pump

Electrical driven 12V

Mechanical driven, manual priming

Max lift fuel pump

Cooling

Radiator cooling

Cooling pump

self-priming impeller pump, PTO driven

Model cooling pump

M12

M16

Minimum supply

18-22 l/min

20-25 l/min

Alternator

synchronous brushless, maintenance free, liquid-cooled

Voltage regulation

capacitor (+ optional: AVR )

Output power at 50Hz, power factor cos phi = 1

12 kW*

16 kW*

Battery charger (alternator including regulator):

50 Amps

* Note that this value must be reduced by the power to drive the cooling fans of the radiators.

Page 26

INSTALLATION SPECIFICATIONS

26 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

3.4 INSTALLATION MATERIALS

FUEL KIT

qty

article no

description

dimensions

50230091

Filter head for fuel strainer/water separator

M14 × 1.5 mm

50221618

Parallel male coupling

M14 - 8 mm

44 2 50221619

Parallel male coupling

M14 - 10 mm

45 2 50221620

Hose connection, outer cone

M16 × 1.5 mm, 8 mm

46 40230092

Filter for fuel strainer/water separator

48 4 50221522

Hose clamp, stainless

10-16 mm

49 2 50221632

Gasket ring

18 × 14 × 1.5 mm

not shown

50221203

Straight coupling

8 mm

not shown

50221252

Barbed-smooth hose nipple

8 mm

TOTAL

40230205

FUEL KIT

OPTIONAL INSTALLATION MATERIALS

qty

article no

description

dimensions

48 1 50221522

Hose clamp, stainless

10-16 mm

not shown

per m

50222020

copper fuel pipe

6 × 8 mm

not shown

per m

50220063

fuel hose

8 × 16 mm

Page 27

INSTALLATION SPECIFICATIONS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 27

BATTERY INSTALLATION KIT (W-SQ 6, 8 and 12)

article no

description

dimensions

61112002

WBC-Handy 20 charger 12V / 2A

157 × 33 × 34 mm

40290093

battery terminal (NEG-)

40290094

battery terminal (POS+)

40290099

M8 battery pole adapter set

40290098

isolation caps (red & black)

502144701

WP-Compact Manual Battery Switch, 300A

72 × 72 × 78 mm

40290106

INSTALLATION KIT FOR BATTERIES UP TO 100 Ah

RECOMMENDED BATTERY

article no

description

dimensions

40290061

AGM-Power 12V 80Ah Absorbed Glass Matt

350 × 167 × 180 mm

BATTERY INSTALLATION KIT (W-SQ16)

article no

description

dimensions

61112007

WBC-Handy 70 charger 12V / 7A

225 × 50 × 50 mm

40290093

battery terminal (NEG-)

40290094

battery terminal (POS+)

40290099

M8 battery pole adapter set

40290098

isolation caps (red & black)

502144701

WP-Compact Manual Battery Switch, 300A

72 × 72 × 78 mm

40290108

INSTALLATION KIT FOR BATTERIES > 100 Ah

RECOMMENDED BATTERY

article no

description

dimensions

40290031

AGM-Power 12V 100Ah Absorbed Glass Matt

328 × 172 × 222 mm

Page 28

INSTALLATION SPECIFICATIONS

28 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

DRY EXHAUST KIT 1½” for W-SQ6, 8, 12 and 16

qty

article no

description

61 1 50220043

Exhaust hose SS 500mm fem./male 11/2”

62 1 50220042

Insulation blanket 35x60 exhaust hose 1 1/2

63 1 50230523

Absorption muffler steel 11/2”

64 1 50230524

Resonance muffler steel 11/2”

65 1 50230525

Insulation blanket 80x75 muffler SDHC 11/2”

66 2 50221403

Pipe nipple 11/2”x300mm galvanised”

67 2 50221423

Parallel male coupling 11/2” galvanised”

68 2 50221413

Straight coupling f/f 11/2”galvanised”

69 3 50221663

U-clamp 48 mm M10

70 3 50221664

Bracket U-clamp 25cm M10/48mm passivated

71 6 50211406

Washer ZP M10

72 6 50211447

Washer spring ZP M10

73 6 50211466

Nut hexagonal ZP M10

75 1 50221473

Elbow 90° m/f galvanised 11/2”

TOTAL

40201875

DRY EXHAUST KIT 1½” for W-SQ6, 8, 12 and 16

RADIATOR COOLING KIT ALTERNATOR 230VAC for W-SQ6, 8 and 12 (see 2.5.2.1 for TopCool alternative)

qty

article no

description

31 1 50230304

Radiator cooler AP 300/2 E 230VAC

32 2 50221103

Straight reducer m/f 1”-3/4”

33 1 50221063

Male nipple 3/4”

34 1 50221043

TEE fittings 3/4”

35 3 50221004

Male hose connection 3/4x20

38 1 50212405

Temperature switch 35-45°C

39 4 50201121

Vibration mounting 30x25

40 4 50211152

Bolt hexagonal ZP M8x16

41 8 50211465

Nut hexagonal ZP M8

42 8 50211405

Washer ZP M8

43 8 50211445

Washer spring ZP M8

44 8 50220011

Hose vacuum SAE100R4 (3/4”) 19x31,5mm

45 6 50221502

Hose clamp stainless19-29

46 8 50221599

Hose support 35x15 mm galvanised

47 1 50230529

Bracket expansion tank for 50230531

47 1 50230531

Expansion tank 20 mm

47 1 50230532

Cap tank 0502 30531

TOTAL

40201878

RADIATOR COOLING KIT ALTERNATOR 230VAC for W-SQ6, 8 and 12

RADIATOR COOLING KIT ALTERNATOR 12VDC FOR W-SQ6 Same as article no. 40201878, except:

qty

article no

description

31 1 50230302

Radiator cooler AP 300/2 E 12VDC

TOTAL

40201872

Radiator cooling kit alternator 12VDC for W-SQ6

RADIATOR COOLING KIT ALTERNATOR 24VDC FOR W-SQ6 Same as article no. 50201878, except:

qty

article no

description

31 1 50230303

Radiator cooler AP 300/2 E 24VDC

TOTAL

40201868

Radiator cooling kit alternator 24VDC for W-SQ6

Page 29

INSTALLATION SPECIFICATIONS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 29

Figure 34: Engine cooling kit, exhaust kit and alternator cooling kit

Page 30

INSTALLATION SPECIFICATIONS

30 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

RADIATOR COOLING KIT ALTERNATOR 230VAC W-SQ16 (see 2.5.2.1 for TopCool alternative)

qty

article no

description

31 1 50230307

Radiator AP 430 230VAC

32 1 50221103

Straight reducer m/f 1”-3/4”

33 1 50221064

Male nipple 1”

34 1 50221044

TEE fitting 1”

35 2 50221010

Male hose connection 1x25

35 1 50221004

Male hose connection 3/4x20

38 1 50212405

Temperature switch 35-45°C

39 4 50201121

Vibration mounting 30x25

40 4 50211152

Bolt hexagonal ZP M8x16

41 4 50211465

Nut hexagonal ZP M8

42 4 50211405

Washer ZP M8

43 8 50211445

Washer spring ZP M8

44 6 50220012

Cooling water hose smooth (1”) 25x34 mm”

1.5

50220011

Cooling water hose smooth (3/4”)18x27 mm”

45 2 50221502

Hose clamp stainless19-29

45 4 50221503

Hose clamp stainless 26-38

47 8 50221599

Hose support stainless 35x12 mm

47 1 50230529

Bracket expansion tank for 50230531

47 1 50230532

Cap tank 0502 30531

47 1 50230531

Expansion tank 20 mm

TOTAL

40201888

Radiator cooling kit alternator 230VAC W-SQ16

RADIATOR COOLING KIT ENGINE 230VAC W-SQ6 (see 2.5.2.1 for TopCool alternative)

qty

article no

description

1 1 50230304

Radiator cooler AP 300/2 E 230VAC

2 2 50221502

Hose clamp stainless19-29

3 1 50221064

Male nipple 1”

4 1 50221044

TEE fitting 1”

5 2 50221010

Male hose connection 1x25

6 1 50221103

Straight reducer m/f 1”-3/4”

7 1 50221004

Male hose connection 3/4x20

8 1 50212409

Temperature switch 87-82°C

9 4 50201121

Vibration mounting 30x25

10 4 50211152

Bolt hexagonal ZP M8x16

11 4 50211465

Nut hexagonal ZP M8

12 8 50211405

Washer ZP M8

13 8 50211445

Washer spring ZP M8

50220013

Cooling water hose, smooth (1¼”) 32x45mm

15 4 50221504

Hose clamp stainless 38-50

16 8 50221597

Hose support ZP 45x25 mm galvanised

17 1 50230529

Bracket expansion tank for 50230531

17 1 50230531

Expansion tank 20 mm

17 1 50230532

Cap tank 0502 30531

1.5m

50220011

Cooling water hose, smooth (¾”) 19x31,5mm

50200005

Hydraulic hose 7,5 × 15mm

20 4 50211437

Washer mudguard ZP 8x30x1,5

21 1 50221522

Hose clamp stainless 10-16

TOTAL

40201879

Radiator cooling kit engine 230VAC W-SQ6

Page 31

INSTALLATION SPECIFICATIONS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 31

RADIATOR COOLING KIT ENGINE 12VDC FOR W-SQ6 Same as article no. 40201879, except:

qty

article no

description

31 1 50230302

Radiator cooler AP 300/2 E 12VDC

TOTAL

40201871

Radiator cooling kit engine 12VDC W-SQ6

RADIATOR COOLING KIT ENGINE 12VDC FOR W-SQ6 Same as article no. 40201879, except:

qty

article no

description

31 1 50230303

Radiator cooler AP 300/2 E 24VDC

TOTAL

40201880

Radiator cooling kit engine 24VDC W-SQ6

RADIATOR COOLER KIT ENGINE 230VAC W-SQ8 (see 2.5.2.1 for TopCool alternative)

qty

article no

description

1 1 50230307

Radiator AP 430 230VAC W-SQ8

2 2 50221502

Hose clamp stainless19-29

3 1 50221064

Male nipple 1”

4 1 50221044

T-stuk-1”

5 2 50221014

Male hose connection 1x35

6 1 50221103

Straight reducer m/f 1”-3/4”

7 1 50221004

Male hose connection 3/4x20

8 1 50212409

Temperature switch 87-82°C

9 4 50201121

Vibration mounting 30x25

10 4 50211152

Bolt hexagonal ZP M8x16

11 4 50211465

Nut hexagonal ZP M8

12 4 50211405

Washer ZP M8

13 8 50211445

Washer spring ZP M8

50220013

Cooling water hose, smooth (1¼”) 32x45mm

15 4 50221504

Hose clamp stainless 38-50

16 8 50221597

Hose support ZP 45x25 mm galvanised

17 1 50230529

Bracket expansion tank for 50230531

17 1 50230531

Expansion tank 20 mm

17 1 50230532

Cap tank 0502 30531

1.5m

50220011

Cooling water hose, smooth (¾”) 19x31,5mm

50200005

Hydraulic hose 7,5 × 15mm

20 4 50211437

Washer mudguard ZP 8x30x1,5

21 1 50221522

Hose clamp stainless 10-16

TOTAL

40201864

Radiator cooler kit engine 230VAC W-SQ8

Page 32

INSTALLATION SPECIFICATIONS

32 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

RADIATOR COOLER KIT ENGINE 230VAC W-SQ12 and W-SQ16 (see 2.5.2.1 for TopCool alternative)

qty

article no

description

1 1 50230311

Radiator AP 430/2 230 VAC W–SQ12 and 16

2 2 50221502

Hose clamp stainless19-29

3 1 50221064

Male nipple 1”

4 1 50221044

T-stuk-1”

5 2 50221014

Male hose connection 1x35

6 1 50221103

Straight reducer m/f 1”-3/4”

7 1 50221004

Male hose connection 3/4x20

8 1 50212409

Temperature switch 87-82°C

9 4 50201121

Vibration mounting 30x25

10 4 50211152

Bolt hexagonal ZP M8x16

11 4 50211465

Nut hexagonal ZP M8

12 4 50211405

Washer ZP M8

13 8 50211445

Washer spring ZP M8

50220013

Cooling water hose, smooth (1¼”) 32x45mm

15 4 50221504

Hose clamp stainless 38-50

16 8 50221597

Hose support ZP 45x25 mm galvanised

17 1 50230529

Bracket expansion tank for 50230531

17 1 50230531

Expansion tank 20 mm

17 1 50230532

Cap tank 0502 30531

1.5m

50220011

Cooling water hose, smooth (¾”) 19x31,5mm

50200005

Hydraulic hose 7,5 × 15mm

20 4 50211437

Washer mudguard ZP 8x30x1,5

21 1 50221522

Hose clamp stainless 10-16

TOTAL

40201877

Radiator cooler kit engine 230VAC W-SQ12 and 16

OPTIONAL INSTALLATION MATERIALS

qty

article no

description

22 1 50230535

Expansion tank 7L + low level alarm switch

Page 33

DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 33

4 DIAGRAMS & DRAWINGS

4.1 LAYOUT GENERATOR CONTROL FOR W-SQ6, 8 AND 12 WITH 230VAC FAN

Fig. 35: Layout generator control for W-SQ6, 8 and 12 with 230VAC radiator fan

Optional control for two speeds fans.

See chapter 4.8

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DIAGRAMS & DRAWINGS

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4.2 LAYOUT GENERATOR CONTROL FOR W–SQ6 WITH 12VDC FAN

Fig. 36: Layout generator control for W-SQ6 with 12VDC radiator fan

Optional control for two speeds fans.

See chapter 4.9

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 35

4.3 LAYOUT GENERATOR CONTROL FOR W-SQ6 WITH 24VDC FAN

Fig. 37: Layout generator control for W-SQ6 with 24VDC radiator fan

Optional control for two speeds fans. See chapter 4.9

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DIAGRAMS & DRAWINGS

36 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.4 LAYOUT GENERATOR CONTROL FOR W-SQ16 WITH 230VAC FAN

Fig. 38: Layout generator control for W-SQ16 with 230VAC radiator fan

Optional control for two speeds fans.

See chapter 4.8

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 37

4.5 WIRING COLOURS W-SQ6, 8 AND 12

Cable code number

colour

cross section

battery > starter motor

red

25 mm²

starter motor > DDC

red

6 mm²

starter motor > LCP

red

2,5 mm²

battery > ground

black

25 mm²

ground > LCP ground (GND)

black

4 mm²

DDC > glow plugs

brown

4 mm²

DDC > starter solenoid

yellow

2,5 mm²

LCP > fuel lift pump +

brown

1,5 mm²

LCP > fuel lift pump -

black

1,5 mm²

DDC > LCD

grey

1,5 mm²

DDC > oil pressure switch

purple

1 mm²

LCP > oil pressure switch

purple/black

1 mm²

DDC > water temperature switch

blue

1 mm²

LCP >water temperature switch

blue/black

1 mm²

DDC > exhaust temperature switch

blue/green

1 mm²

LCP > exhaust temperature switch

blue/rose

1 mm²

DDC > fuel solenoid (hold)

green

1,5 mm²

DDC > fuel solenoid (pull)

pink

1,5 mm²

DDC > fuel solenoid (com.)

black

1,5 mm²

B+ terminal alternator > starter motor

red

6 mm²

DDC >R terminal alternator

wit

1,5 mm²

DDC > L terminal alternator

orange

1,5 mm²

DDC > current measuring transformer

black

1 mm²

DDC >current measuring transformer

red

1 mm²

DDC > LCP

black

1,5 mm²

DDC > LCP

red

1,5 mm²

DDC > LCP

red/green

1,5 mm²

DDC > generator AC output

brown

1 mm²

DDC > generator AC output

blue

1 mm²

Page 38

DIAGRAMS & DRAWINGS

38 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.6 WIRING COLOURS W-SQ16

Cable code number

colour

cross section

battery > starter motor

red

35 mm²

starter motor > DDC

red

6 mm²

starter motor > LCP

red

2,5 mm²

battery > ground

black

35 mm²

ground > LCP ground (GND)

black

4 mm²

DDC > glow plugs

brown

4 mm²

DDC > starter solenoid

yellow

2,5 mm²

DDC > LCD

grey

1,5 mm²

DDC > oil pressure switch

purple

1 mm²

LCP > oil pressure switch

purple/black

1 mm²

DDC > water temperature switch

blue

1 mm²

LCP >water temperature switch

blue/black

1 mm²

DDC > exhaust temperature switch

blue/green

1 mm²

LCP > exhaust temperature switch

blue/rose

1 mm²

DDC > fuel solenoid (hold)

green

1,5 mm²

DDC > fuel solenoid (pull)

pink

2,5 mm²

DDC > fuel solenoid (com.)

black

2,5 mm²

B+ terminal alternator > starter motor

red

6 mm²

DDC >R terminal alternator

wit

1,5 mm²

DDC > L terminal alternator

orange

1,5 mm²

DDC > current measuring transformer

black

1 mm²

DDC >current measuring transformer

red

1 mm²

DDC > LCP

black

1,5 mm²

DDC > LCP

red

1,5 mm²

DDC > LCP

red/green

1,5 mm²

DDC > generator AC output

brown

1 mm²

DDC > generator AC output

blue

1 mm²

DDC=Digital Diesel Control Unit LCP=Local Control Panel

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 39

4.7 AC WIRING DIAGRAM 230V / 50HZ

Fig. 39: AC wiring diagram

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DIAGRAMS & DRAWINGS

40 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.8 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 230VAC

Fig. 41: Electrical diagram fan control using 230V

AC radiator fans – with two speeds fans (optional)

Fig. 40: Electrical diagram for standard fan control

using 230V AC radiator fans

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 41

4.9 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 12 / 24 VDC

Fig. 42: Electrical diagram fan control using 12V or 24V

DC radiator fans (optional)

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DIAGRAMS & DRAWINGS

42 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.10 WIRING DIAGRAM ELECTRONIC GOVERNOR (STANDARD FOR W-SQ6, 8 AND 12)

Fig. 43: Electronic governor

In addition to the mechanical governor, the W-SQ6, 8 and 12 are 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 (3000 RPM =50 Hz) of the alternator. Under full load the RPM of the models that have only a mechanical governor can drop 75 RPM (=2.5 Hz) at full load and will go further down or collapse when further loaded. However the engines with the electronic governor will keep the RPM and frequency at the set value. As the voltage is related to the frequency, the voltage will be more stable as well. The RPM represents power and the alternator performs better as well on a higher speed. Models with an electronic governor will bring more power. So the electronic governor offers three advantages: a more stable frequency and voltage and more power.

The electronic governor system contains two parts:

1 The actuator controls the engine speed. This actuator

replaces the standard hold solenoid that is on all other

mechanical controlled WhisperPower engines. The

actuator controls the RPM directly on the fuel rack

inside the fuel pump without levers and other

mechanical transmissions. 2 A microprocessor keeps the speed at the set value by

controlling the actuator. The microprocessor is

programmed at the WhisperPower factory and many

parameters are set to perform well. It should not be

necessary to make adjustments. 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.

The WhisperPower electronic governor does not need a pickup device in the flywheel housing that counts the passing tooth of the flywheel and determines the exact RPM of the engine, because the processor uses the 50 Hz of the AC output voltage as a reference.

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 43

4.11 REMOTE CONTROL PANEL DRAWINGS

Fig. 44: WhisperPower remote panel

The remote panel comes in a carton that can be used as a template to drill the mounting hole.

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DIAGRAMS & DRAWINGS

44 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.12 DIMENSIONS W-SQ6

Fig. 45: Outer dimensions (mm) W-SQ6

CONNECTIONS W-SQ6:

BOX DIMENSIONS W-SQ6:

• exhaust:

1 ½” • length

80.5 cm (31.7’)

• fuel hose:

5/16” (8 mm)

• width

52.5 cm (20.7’)

• radiator alternator:

3/4” (19 mm)

• height

58.0 cm (22.8’)

• radiator engine:

1” (25.4 mm)

• weight

240 kg (530 Lbs)

• battery +:

AWG 2 (25 mm²)

• battery -:

AWG 2 (25 mm²)

POWERCABLES ISO 13297 annex A

• 3 x AWG 12 (4 mm²) (not included)

REMOTE CONTROL:

• 15 meter (45 ft) 8 wire communication cable (included)

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 45

4.13 DIMENSIONS W-SQ8

Fig. 46: Outer dimensions (mm) W-SQ8

CONNECTIONS W-SQ8:

BOX DIMENSIONS W-SQ8:

• exhaust:

1 ½” • length

900 mm (35.4”)

• fuel hose:

5/16” (8 mm)

• width

575 mm (22.6”)

• radiator alternator:

3/4” (19 mm)

• height

640 mm (25.2”)

• radiator engine:

1¼” (32 mm)

• weight

335 kg

• battery +:

AWG 2 (25 mm²)

• battery -:

AWG 2 (25 mm²)

POWERCABLES ISO 13297 annex A (not included)

• 3x6 mm² (not included)

REMOTE CONTROL:

• 15 meter 8 wire communication cable (included)

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DIAGRAMS & DRAWINGS

46 December 2016 / W-SQ6/8/12/16 for mobile applications / EN

4.14 DIMENSIONS W-SQ12

Fig. 47: Outer dimensions (mm) W-SQ12

CONNECTIONS W-SQ12:

BOX DIMENSIONS W-SQ12:

• exhaust:

1 ½” • length

1060 mm (41.7”)

• fuel hose:

5/16” (8 mm)

• width

575 mm (22.6”)

• radiator alternator:

3/4” (19 mm)

• height

640 mm (25.2”)

• radiator engine:

1¼” (32 mm)

• weight

380 kg

• battery +:

AWG 2 (25 mm²)

• battery -:

AWG 2 (25 mm²)

POWERCABLES ISO 13297 annex A

• 3x10 mm² (not included)

REMOTE CONTROL:

• 15 meter 8 wire communication cable (included)

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DIAGRAMS & DRAWINGS

EN / W-SQ6/8/12/16 for mobile applications / December 2016 47

4.15 DIMENSIONS W-SQ16

Fig. 48: Outer dimensions (mm) W-SQ16

CONNECTIONS W-SQ16:

BOX DIMENSIONS W-SQ16:

• exhaust:

1 ½” • length

1160 mm (45.7”)

• fuel hose:

5/16” (8 mm)

• width

680 mm (26.8”)

• radiator alternator:

3/4” (19 mm)

• height

700 mm (27.6”)

• radiator engine:

1¼” (32 mm)

• weight

454 kg

• battery +:

35 mm²

• battery -:

35 mm²

A template to drill the mounting holes of the W-SQ16 is included in the delivery.

POWERCABLES ISO 13297 annex A

• 3x16 mm² (not included)

REMOTE CONTROL:

• 15 meter 8 wire communication cable (included)

Page 48

Kelvinlaan 82, 9207 JB Drachten, Netherlands

Tel : + 31-512-571550 / Fax : + 31-512-571599

www.whisperpower.com / info@whisperpower.com