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Whisper Tech WhisperGen 3000 Series Installation And Commissioning Manual

Personal power station, 12v, 24v, diesel, kerosene, marine, land based
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Personal Power Station
I
NSTALLATION
A
C
ND
OMMISSIONING
PPS16
Model:
3000 and 7000 series
Configurations: 12V
M
24V
Diesel
Kerosene
Marine
Land based
ANUAL

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  • Page 1 Personal Power Station NSTALLATION OMMISSIONING ANUAL PPS16 Model: 3000 and 7000 series Configurations: 12V Diesel Kerosene Marine Land based...
  • Page 2 This publication or part thereof, may not be reproduced in any form by any method, for any purpose. For conditions of use and permission to use this document for any form of publication, contact Whisper Tech Ltd. Whisper Tech Ltd produces documentation in English only.

  • Page 3: Table Of Contents

    Page Introduction Installation checklist ................. 1 1. Transporting the WhisperGen ................1 2. Unpacking the WhisperGen ................1 3. Mounting the WhisperGen ................4 4. Pressurising the WhisperGen ............... 5 5. Fitting the exhaust heat exchanger ........6 6. Plumbing the coolant circuits for the WhisperGen The primary coolant circuit ..................
  • Page 4 Page Checklist for commissioning ..............27 12. The control panel user settings ....................27 13. Battery settings ................... 29 14. WhisperGen check ......29 15. Monitoring the WhisperGen using the control panel ........30 16. Monitoring the WhisperGen using a computer ..........
  • Page 5 Minimum clearances, services layout, and mounting bolts ..2 Figure 1: Primary coolant circuit – series ............7 Figure 2: Primary coolant circuit – parallel ............. 8 Figure 3: Plumbing the secondary coolant circuit – marine systems..10 Figure 4: Setting up the battery ..............
  • Page 6 The WhisperGen The WhisperGen is a unique personal power station providing cogeneration of heat and electrical energy. The WhisperGen is capable of charging and managing a lead-acid battery bank to provide a DC electrical power supply. It also provides heat energy in the form of hot coolant for space heating and domestic hot water generation.

  • Page 7: Installation Checklist

    To validate the authorised agent’s warranty for the WhisperGen the installer shall: • install the WhisperGen as per the instruction manual • complete the installation checklist in full. For checkpoints which are not applicable for this installation enter “n/a”. • send a copy of the installation checklist to your authorized WhisperGen agent.
  • Page 8 Before you install the WhisperGen Read and understand the PPS16 User’s manual. Attend the WhisperGen installation course. Read, understand, and comply with the relevant local authority regulations which apply to this installation. Read, understand and comply with the Recreational Craft Directive 94/25/EC, issued by the Council of the European Community.
  • Page 9 Page Task Details Complete The minimum distance between the top of the WhisperGen and the outlet from the header tank is 100mm. The volume of the header tank is at least 5% of the total volume of coolant in the circuit. The distance between the self-bleeding header tank and the coolant circulation pump is no more than 300mm.
  • Page 10 Page Task Details Complete The wiring is connected according to the wiring diagram supplied with the WhisperGen. A good quality corrosion inhibitor, suitable for aluminium, and other components of the system, has been used in the primary coolant circuit. The primary coolant circuit has been bled of air, and the coolant is flowing at a minimum rate of 6 litres per minute.
  • Page 11 Setting up the exhaust system The exhaust pipe: • is short with few bends The exhaust outlet: • is fitted with a weather protection cowling made from a suitable material; • will always have a slope of at least 10 degrees relative to the horizon; •...

  • Page 12: Transporting The Whispergen

    Transporting the WhisperGen The WhisperGen shall be transported: ∙ upright; ∙ bolted to a pallet and protected with a wooden cover labeled “Fragile”, and “No stack”; ∙ separated from lead acid batteries; ∙ with the exhaust heat exchanger unbolted from the burner, and clamped to the enclosure base;...
  • Page 13 Figure 1: Minimum Clearances, Services, VIEW B and Mounting bolts layout . (All dimensions in mm). VIEW A VIEW Marine only SECONDARY COOLING WATER IN WATER IN 800mm minimum clearance Land only PRIMARY HEATING WATER IN EXHAUST FRESH WATER IN PRIMARY HEATING SECONDARY COOLING PRIMARY HEATING...
  • Page 14 ⅛ BSPP Female VIEW B BACK AIR BOX 650mm minimum clearance AIR INTAKE SLOT MOUNTING HOLE 170mm minimum 4 OFF clearance WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...

  • Page 15: Pressurising The Whispergen

    Pressurising the WhisperGen The WhisperGen is a pressurised device. Contact your distributor if disassembly of the core Warning: engine is required. The maximum pressure is limited by a pressure relief valve. This valve shall not be adjusted. A Warning: pressure relief valve is set at the factory, and any adjustment voids all warranties and can result in an unsafe and/or unreliable machine.

  • Page 16: Fitting The Exhaust Heat Exchanger

    Fitting the exhaust heat exchanger The exhaust heat exchanger is de-coupled from the burner during shipping. To fit the exhaust heat exchanger: Unbolt and remove the clamp holding the exhaust heat exchanger to the enclosure base. Refit the bolt to the exhaust heat exchanger. Fit the supplied gasket between the exhaust heat exchanger and the burner.

  • Page 17: Plumbing The Coolant Circuits For The Whispergen

    Plumbing the coolant circuits for the WhisperGen A corrosion inhibitor shall be used in the primary coolant circuit because the engine is largely Warning: manufactured from aluminium alloy. See also section 8: Filling and bleeding the coolant circuits. The WhisperGen has three fluid circuits: ●...

  • Page 18: Figure 2: Primary Coolant Circuit – Series

    Figure 2: Primary coolant circuit - series WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...

  • Page 19: Figure 3: Primary Coolant Circuit – Parallel

    Figure 3: Primary coolant circuit – parallel WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...

  • Page 20: Plumbing The Primary Coolant Circuit

    6.3 Plumbing the primary coolant circuit See Figure 2: WhisperGen services layout, Figure 3: Primary coolant circuit – series; and Figure 4: Primary coolant circuit - parallel. The WhisperGen primary inlet and outlet connections are ISO Rp ¾ BSP female threads. They are on the back of the WhisperGen enclosure, marked “PRIMARY HEATING IN”...

  • Page 21: Plumbing The Secondary Coolant Circuit - Marine Systems

    6.4 Plumbing the secondary coolant circuit – marine systems See Figure 5: Plumbing the secondary coolant circuit. The inlet and outlet for the secondary coolant circuit shall not be connected to the inlet or outlet Warning: of another system. The inlet and the seawater pump shall be under the water line by a minimum of 200mm at all Warning: times.

  • Page 22: Setting Up The Battery And Control System

    Setting up the battery and control system The WhisperGen electrical wiring shall comply with your local Electrical Code of Practice for Warning: extra low voltage installations. For marine installations, The Recreational Craft Directive 94/25/EC shall apply to the Warning: installation. It has specific requirements for electrical connections and battery installation. All positive connections from power sources and loads, except the battery, shall be made to the Warning: battery side of the WhisperGen circuit breaker.

  • Page 23: Mounting The Control Panel

    Mounting the control panel See Figure 7: The control panel To mount the control panel: Select a site for the control panel which is dry and which allows free access for the communication cable. Undo the clamp on the back of the control panel. Cut a rectangular hole 127mm wide x 114mm high for mounting the control panel.

  • Page 24: Connecting The Battery

    Connecting the battery See Appendix A and Appendix B for recommended components. See Figure 8: Wiring diagram To connect the battery: Connect the positive lead. This is connected to the positive terminal of the battery bank via an isolating switch, and a battery fuse or circuit breaker. Connect the negative lead from the battery negative terminal to the current shunt which is supplied with the WhisperGen.

  • Page 25: Control System Connection Points

    7.3 Control system connection points 7.3.1 Primary coolant pump The power to the primary coolant pump terminals is supplied directly from the alternator of the WhisperGen. The pump will continue to run if the WhisperGen is running, and is disconnected from the batteries. The WhisperGen turns on the water pump when it is started and turns it off when it is stopped and has cooled down.
  • Page 26 7.3.5 External Digital Out The maximum output current is 100mA. The External Digital Out is a low current, 5V digital output which allows the WhisperGen to control the temperature of the coolant by switching an optional additional water heater on and off. The output is logic only and cannot drive a relay, but is suitable for digital input to another device.
  • Page 27 WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...

  • Page 28: Filling And Bleeding The Coolant Circuits

    Filling and bleeding the coolant circuits A corrosion inhibitor shall be used in the primary cooling circuit because the engine is largely Warning: manufactured from aluminium alloy. A good quality corrosion inhibitor shall be used. If ethylene glycol, (automotive anti-freeze) is used as the corrosion inhibitor, a minimum of 35% Warning: undiluted glycol to 65% fresh water solution shall be used for the coolant.
  • Page 29 Make sure that the coolant is flowing at a minimum flow rate of 6 litres per minute. Check the primary coolant circuit for leaks. Open the bleed valves as necessary to remove air from the circuit. To bleed the secondary coolant circuit: Access the Main Menu on the control panel.

  • Page 30: Setting Up Combined Heating And Battery Charging

    Setting up combined heating and battery charging 9.1 Setting up hot water heating If a thermostat is used to start the WhisperGen, it shall be set 5°C below the coolant Warning: temperature set point, (refer to the control panel). If the thermostat is set higher than the coolant temperature set point, the WhisperGen will not be able to heat the water in the hot water cylinder/boiler to a high enough temperature to turn the WhisperGen off.

  • Page 31: Setting Up The Fuel System

    10. Setting up the fuel system The WhisperGen burner is fuel specific and can operate only on the fuel it has been configured Warning: for. The evaporator at the top of the burner is marked ‘D’ for diesel and ‘K’ for kerosene. For the diesel burner use only good quality automotive diesel (BS2869: 1988 burner fuel class Warning: D) with the WhisperGen.

  • Page 32: Bleeding The Fuel System

    10.1 Bleeding the fuel system At least twice the volume of fuel in the entire fuel line connecting the fuel tank to the burner evaporator, shall be bled. For example, if the fuel line measures 3mm in inner- diameter and 5 metres in length, then a minimum of 70ml of fuel shall be bled. The default Fuel Bleed function will bleed the system in pulses for 60 minutes.

  • Page 33: Figure 8: Fuel Pump And Fuel Line Installation

    Figure 8: Fuel pump and fuel line installation Back of WhisperGen 2m max WATER IN PRIMARY HEATING WATER IN WATER OUT BATT −− FUEL The fuel line shall be a maximum of 8m in 1.25m max length. Fuel tank Fuel tank Fuel pump Fuel filter...

  • Page 34: Setting Up The Exhaust System

    11. Setting up the exhaust system The exhaust outlet shall not be connected to the exhaust system of another engine or heating Warning: device. The WhisperGen exhaust shall be freely vented to the outside at all times. Warning: Condensate forms down the entire length of the exhaust pipe under all operating conditions. Warning: Condensate drains shall be run from all points in the exhaust where condensate is likely to be trapped.

  • Page 35: Fresh Water Flushing Of The Exhaust Heat Exchanger

    To set up the exhaust system: Attach the exhaust pipe to the exhaust exit at the back of the WhisperGen. Make sure that the exhaust pipe will always have a slope of 10° relative to the horizon. When the WhisperGen is not running, use the Bleed Air function on the control panel (or push the start and then the stop button), to make the burner fan operate at 100%.

  • Page 36: Figure 9: Exhaust Piping For Marine And Land Based Systems

    Figure 9: Exhaust piping for marine and land based systems Ideal Exhaust Piping WhisperGen Least 10° Waste-Water Piping Unacceptable Exhaust Piping Starboard Port WhisperGen WhisperGen When the boat When the boat heels to starboard, heels to port, the Port Starboard condensate will exhaust will be Waste-Water Piping...
  • Page 37 Unacceptable Ideal Exhaust Piping Exhaust Piping Low Points Not Drained WhisperGen WhisperGen Less Less Than Than WhisperGen 10° 10° At Least 10° To Waste-Water Piping To Waste-Water Piping Air Trap WhisperGen Waste-Water Piping Less Than 10°, Low Points Not At Least Drained WhisperGen 10°...
  • Page 38 To validate the warranty for the WhisperGen the commissioner shall: • complete the commissioning checklist in full. For checkpoints which are not applicable, enter “n/a” • send a copy of the commissioning checklist to the authorised WhisperGen supplier. WhisperGen PPS16 Commissioning checklist. WhisperGen Engine Serial number Date of commissioning Full name:...
  • Page 39 Page Task Details Complete User’s manual read and understood Installation checklist complete WhisperGen checked, complete and undamaged. The WhisperGen is pressurised with nitrogen gas. Microprocessor monitoring understood. Computer connected to WhisperGen for commissioning. Battery Volts are 0.6 ± 0.1 greater than the Bus Voltage when WhisperGen is in Standby mode.
  • Page 40 Fill out the values below when commissioning is complete. Item Details Complete Full power operating parameters Complete this section when: • Runtime (Min) is greater than 45; • Bulk charge is displayed on the control panel; • Coolant Temp is between 67 and 72; and •...
  • Page 41 User Adjustable Settings Details Complete LCD display contrast setting OK LCD display back light setting OK Heat manage set to Temp setpoint set to Auto-charge set to Ext. Control set to Ext. Control Mode set to Max Run Hhours set to Enable Starts set to Second StartFuel1 value Name and signature of commissioner.

  • Page 42: The Control Panel User Settings

    12. The control panel user settings Refer to the User’s Manual for instructions for setting: • LCD Display Contrast • LCD Back Lighting • Heat Manage • Temp Setpoint • Auto-charge • Ext. Control • Ext Control Mode • Max Run Hours 13.
  • Page 43 The battery settings are: • Battery Capacity This is the battery capacity in ampere hours, at the 20 hour rate of the battery. • Max Battery Discharge This is the amount the battery can be discharged as a decimal percentage of the Battery Capacity before the Auto-Charge function will automatically start the WhisperGen, charge the battery, and then stop the WhisperGen.

  • Page 44: Whispergen Check

    14. WhisperGen check To check the WhisperGen before commissioning: 1. Remove the enclosure cover and ensure that: • spare parts, tools and the User’s Manual are present; • there is no damage to the WhisperGen engine; • the burner is correctly positioned; and •...

  • Page 45: Monitoring The Whispergen Using A Computer

    16. Monitoring the WhisperGen using a computer. This option provides monitoring of the WhisperGen by a personal computer and “Micromon MO” software which shall be used to aid commissioning of the WhisperGen. See Figure 11: Micromon MO screen. The Micromon MO software allows: •...

  • Page 46: Running The Whispergen For The First Time

    17. Running the WhisperGen for the first time To run the WhisperGen for the first time: Complete sections 1 to 15 of this manual. Connect the monitoring computer to the WhisperGen and start Micromon MO. Put the WhisperGen into Standby mode by pressing the start button for five seconds.

  • Page 47: Heat Dump Test

    Write down the O2 start value which is about variable number 70 on the Micromon MO variables screen. The WhisperGen goes into a stabilising period next, while the burner stabilises. This will last for about a minute. At the end of the stabilising stage check that: •...

  • Page 48: User Selectable Function Testing

    19. User selectable function testing To check the Heat Manage operation: Turn Heat Manage to on and switch on the radiators or convection heaters. Start the WhisperGen. Wait for the battery charge cycle to finish absorb charging. Check that the WhisperGen is running in Float charge and is providing heat to the radiators and convection heaters.

  • Page 49: Full Power Operating Parameters

    20. Full power operating parameters To set the full power operating parameters: Make sure that the exhaust temperature of the WhisperGen is less than 30°C. The secondary coolant bleed function and the fan air bleed function can be used to speed up cooling of the WhisperGen.
  • Page 50 Complete the Commissioning Details section at the back of the User’s Manual. Complete the Commissioning Checklist in the Installation and Commissioning manual and return it to the Whisper Tech Limited and the distributor. WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...
  • Page 51 APPENDIX A: Recommended components for the coolant circuits The following primary and secondary coolant circuit pumps are recommended. Other circulation pumps of the same, or slightly larger, capacity can be used. Pumps should be sized to provide a minimum flow rate of 6 l/min in the primary and secondary circuits.
  • Page 52 Coolant The primary circuit coolant must contain a corrosion inhibitor because the engine is largely manufactured from aluminium alloy. If ethylene glycol is used as the corrosion inhibitor, a minimum of 35% undiluted glycol to 65% fresh water solution shall be used. It is essential that the primary coolant is clean and free fro debris.
  • Page 53 APPENDIX C: Recommendation for circuit breaker The recommended circuit breaker is Blue Seas type 7103 (125A), 30V or similar. A 200 amp fuse can be used with an isolating switch. WhisperGen PPS16 Installation and Commissioning Manual Rev: 080801...

This manual is also suitable for:

Whispergen 7000 seriesWhispergen pps16

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