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WhisperGen PPS16-24MD Commissioning Manual

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  • Page 3 This publication describes the state of this product at the time of its publication and may not reflect the product at all times in the future. Patents granted and pending worldwide. Whisper Tech, WhisperGen, Personal Power Station, and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited. Title...
  • Page 5 WhisperGen , please refer to the exercises all due care. warranty provided by the supplier of your WhisperGen Whisper Tech accepts no liability for direct, indirect, Unless otherwise noted, reference to brand names, product incidental, special, or consequential damages resulting...

  • Page 6: Table Of Contents

    Contents Purpose of this manual..............................1 Symbols in this manual ..............................1 Before you travel ................................2 Equipment needed ................................3 Guidelines to follow ................................4 Pre-start guidelines (Power OFF) ............................ 4 Visual check................................4 Checking and adjusting nitrogen pressure....................... 5 Determining battery type and capacity........................

  • Page 7: Purpose Of This Manual

    WhisperGen PPS16-24MD diesel-fired generator with 24 V DC output and their associated systems, into recreational craft. The WhisperGen must not be used in any other capacity. Use the Commissioning Checklists in Appendix B with the Default Settings in Appendix A of this guide to complete commissioning.

  • Page 8: Before You Travel

    DC Installation Manual WP 5012-002-01). Ensure that you take all equipment needed as listed. You may need to arrange delivery of nitrogen to pressurise a WhisperGen Upon completion of Commissioning, copy the completed checklists and fax to Whisper Tech NZ +64 (3) 363 9284 or email a completed checklist to: service@whispergen.com...

  • Page 9: Equipment Needed

    Optional Brand/Model: Bluewhite Industries F400 gauge Tool kit Documentation: Current DC Installation Manual and DC User's Manual This DC Commissioning Guide and checklists to complete and return Manuals can be downloaded from www.whispergen.com if you don't have current printed copies of these manuals available.

  • Page 10: Guidelines To Follow

    Checking the Coolant Visual check It is important to visually check the overall heating and electrical system into which the WhisperGen has been installed. If the wider system does not meet the design and component specifications defined in the Installation Manual, then there could be risks to the safety of operators and to the performance and reliability of the unit.

  • Page 11: Checking And Adjusting Nitrogen Pressure

    Adjust the regulator if necessary. Open the primary valve. The WhisperGen starts to pressurise. Allow the pressure gauge to stabilise. Introduce Nitrogen slowly. Add Nitrogen at a rate of 1 bar / minute. Adding Nitrogen too quickly damages WhisperGen seals.

  • Page 12: Determining Battery Type And Capacity

    Close the secondary valve and close the nitrogen bottle isolating valve. Once the pressure is checked and confirmed to be at the correct level, leave the pressure gauge attached to the WhisperGen as it will be required again later in the commissioning process.

  • Page 13: Checking Battery Bank Connections

    Power flows between the WhisperGen and battery bank via two power Overview cables connected to the terminals of the battery bank. The WhisperGen also monitors the battery bank voltage, current, and temperature via electrical wires connected to the battery bank. The WhisperGen should not be running when you check the connections.

  • Page 14: Checking The Fuel

    The fuel level should be checked regularly to ensure a constant fuel supply to Overview the WhisperGen . How often the fuel needs to be checked and replenished depends on the operating conditions of the WhisperGen and the size of the fuel tank. In general, the WhisperGen consumes 0.5 to 0.85 litres of fuel per hour of...

  • Page 15: Checking The Coolant

    Checking the Coolant The coolant level should be checked regularly to ensure a constant Overview circulation of coolant through the WhisperGen . How often the coolant needs to be checked and replenished depends on the size of the coolant header tank and the coolant circuit.

  • Page 16: Pre-Start Guidelines (Power On)

    Overview The primary coolant system must be filled and then the pump operated via the WhisperGen control panel to bleed air from the system. Use only the specified coolant. Use of incorrect coolant will result in corrosion to the WhisperGen.
  • Page 17 Pre-start guidelines (Power ON) Fill and bleed the primary coolant system After 5 minutes of user inactivity, the control panel reverts to the default screen. If you need to go back to the default screen before this, press Left Arrow until it is displayed. Slowly unscrew the bleed valve on the exhaust heat exchanger, until air free coolant runs from the bleed.

  • Page 18: Bleed The Secondary Cooling System

    Pre-start guidelines (Power ON) Bleed the secondary cooling system Bleed the secondary cooling system Overview Bleeding the secondary coolant system requires the opening (and checking) of the seacocks, operation of the secondary coolant pump from the control panel, and visual confirmation of the required flow from the outlet.

  • Page 19: Bleed The Fuel System

    Procedure To bleed the fuel system: Turn the fuel switch on the front of the WhisperGen to ON. Make sure the isolation valve at the fuel tank is OPEN. Disconnect the fuel line from the evaporator.

  • Page 20: Battery Charging Overview

    Pre-start guidelines (Power ON) Battery charging overview Battery charging overview Every time the WhisperGen is operated, it charges the battery bank and Battery charging cycles is in one of these three charging states depending on settings. There are three states for a typical charging cycle as shown in the diagram below: User controller settings affect the bulk-charging and auto-charging settings only.

  • Page 21: Connect And Check Micromon

    Connect and check Micromon Connect a computer with Micromon installed to the WhisperGen Procedure You can connect Micromon to a WhisperGen...
  • Page 22 Pre-start guidelines (Power ON) Connect and check Micromon Start Micromon and check the highlighted items on the main screen: Battery Voltage (1), Bus Voltage (2), Battery Ah (3) and Comms Link (4) highlighted Check the communication link is working. Reconnect the cabling as listed previously and restart Micromon if this is not working.

  • Page 23: Setting Maintenance Mode

    Setting maintenance mode Micromon has two modes: Observation mode and Maintenance mode. Micromon modes Micromon starts in Observation mode. Observation mode allows you to start and stop WhisperGen and view variables. Maintenance mode allows you to adjust variables and program the WhisperGen...

  • Page 24: Setting Variables

    After checking and bleeding the WhisperGen coolant and fuel, check the following numbered variables (as shown highlighted in the above screenshot) in Micromon before starting the WhisperGen Battery Capacity (BattSize): Description: This is the battery capacity in ampere-hours of the battery.
  • Page 25 Setting: Ensure the Itail% value set is within the battery charging capacity (35A for 24V systems and 70A for 12V systems) of the WhisperGen calculating the current needed. Apply the formula Battery Ah x Tail Current % = Current needed.
  • Page 26 Default: The default O2runfact setting is 0.5 for both 24V and 12V. Check that O2runfact is set between 0.4 and 0.55 for 24V and 12V before starting the WhisperGen Setting: Decrease O2runfact to make the mixture richer and increase O2runfact to make the mixture leaner.
  • Page 27 Testmode is set to 2 by default. Setting: Only set Testmode to 1 to perform exhaust gas analysis. Do not leave the WhisperGen running with Testmode set to 1 for more than 1 hour for a test run since damage can result to critical components if the engine is operated with Testmode set to 1.

  • Page 28: Monitoring Variables

    Monitoring variables 10. Float Voltage (Vfloat) Description: This is the voltage that the battery is held at if the WhisperGen continues running after the battery has been defined by the system as being fully charged. The charged state of the battery bank is maintained with a small current and reduced voltage.
  • Page 29 Pre-start guidelines (Power ON) Monitoring variables Check the Comms Link is active in the top left of the Micromon screen. If WhisperGen startup timings the display on the User Controller LCD and Micromon LCD do not match then ensure that Micromon is connected and running.

  • Page 30: Test Run Guidelines

    Started WhisperGen by pressing the Start button on the WhisperGen user control panel. Test run checks are performed after the WhisperGen has been started and is running. After starting, the WhisperGen displays the following states on the LCD before running: 1.

  • Page 31: Monitoring Micromon

    Clamp Volts Battery Ah Battery Amps Battery Volts Battery Watts are displayed on the WhisperGen User Controller LCD not on the representative WhisperGen LCD shown on Micromon. You will need to observe and record Battery Watts as displayed on the User...

  • Page 32: Run Factor

    Test run guidelines Run factor Run factor A key variable that may be altered by the Commissioning Agent during the test run is the 'Run Factor' setting. The Run Factor determines the air/fuel mixture that, in turn, affects the air and oxygen % variables being measured by the gas analyser.

  • Page 33: Controller Setting Guidelines

    The Control Panel The control panel is the main interface between the user and the WhisperGen. The control panel allows the user to start and stop the WhisperGen, change settings, and view performance. It alerts the user to system faults and allows access for commissioning and service.

  • Page 34: Setting The Lcd Display Control And Backlight

    Hold down Left Arrow and press the Down Arrow press repeatedly until the desired contrast is achieved. If the battery bank is disconnected from the WhisperGen , LCD contrast settings are retained for up to approximately one month after the disconnection.
  • Page 35 If a Max Run Hours setting of less than 25 has been set, the WhisperGen will automatically stop when the Max Run Hours set value is reached. See...
  • Page 36 Controller setting guidelines Setting the temperature and maximum run hours Setting the Coolant Temperature Whenever it is running, the WhisperGen regulates the temperature of the coolant circulating through it. The coolant is used for space and domestic water heating. By default, the temperature of the coolant is maintained at approximately 60°C.
  • Page 37 The default display will re-appear automatically after a few minutes of inactivity on the control panel. If the Max Run Hours setting is less than 25, the WhisperGen will automatically stop when the Max Run Hours set value is reached, even if the battery bank is not yet fully charged.

  • Page 38: Setting The Auto-Charge And External Control

    Setting the auto-charge and external control Setting the auto-charge and external control Auto-Charging the Battery Bank You can set the WhisperGen to automatically start and charge the battery bank when the battery bank charge level is low. To set the WhisperGen to auto-charge the battery bank: Access the User Menu on the control panel.
  • Page 39 WhisperGen stops automatically and returns to the standby mode. Regardless of heat management settings, the WhisperGen will stop once the battery bank is fully charged if the WhisperGen been started by the auto-charge function. While the WhisperGen is auto-charging the battery bank, you can stop it at any time by pressing STOP on the control panel.
  • Page 40 You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel. The effect of starting or stopping the WhisperGen using a remote switch is similar to pressing START or STOP on the control panel. Refer to section...

  • Page 41: Appendix A - Default Micromon Settings

    Appendix A Default Micromon Settings Appendix A Default Micromon Settings DEFAULT DEFAULT Micromon Description (Units) Micromon Field Name SETTINGS SETTINGS 24 Volt 12 Volt Air Ramp Down (Diesel) Airrampdown (diesel) 0.75 0.75 Auto Charge AutoCharge Auxiliary Negative AuxNeg Auxiliary Positive AuxPos Battery Capacity (Ah) BattSize...

  • Page 42: Appendix B - Commissioning Checklists

    1. Complete the commissioning checklist in full, either hard copy or electronic. 2. Mail, fax or email copy of commissioning checklist to WhisperGen Ltd, New Zealand. 3. Sign owner's copy of Installation Checklist to validate the warranty.
  • Page 43 Block temperature set point adjusted to 45 Battery Amps read negative when load is applied Battery Volts are 0.6+ 0.1 greater than the Bus Voltage when the WhisperGen is in Standby mode 0.46 First 'Run Factor' value Ambient Air temperature (approx)
  • Page 44 Appendix B Commissioning Checklists FULL POWER OPERATING PARAMETERS AND VARIABLES Complete this section when: 1. Runtime (Min) is greater than 45 2. Bulk Charge is displayed on the control panel (If this is not possible, Test Mode 1 may have to be selected to enable a full power parameter check) 3.
  • Page 45 Appendix B Commissioning Checklists RUN LOG Record all Variables at 5 minute intervals; Check and adjust Run Factor as required. Record all Variables and Full Power Operating Parameter Values at the 45 minute mark Final Record at 60 minute runtime before shutdown and sign off. Record 5 MIN 10MIN...

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