WhisperGen PPS16 User Manual
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WhisperGen PPS16 User Manual

Personal power station
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Summary of Contents for WhisperGen PPS16

  • 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 User's Manual - Models PPS16-12MD, PPS16-24MD Part No.
  • 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

    Replacing the Glow Plug............................49 Replacing Fuses ..............................50 Replacing the FID ..............................53 Replacing the Oxygen Sensor ..........................56 Replacing the Evaporator Wick..........................58 Replacing the Evaporator............................60 Flushing the Exhaust Heat Exchanger........................63 Winterising the WhisperGen ..........................64...
  • Page 7 A reminder of safety practices or unsafe practices which could result in personal injury or damage to associated equipment. A reminder of safety practices or unsafe practices which could result in damage to the WhisperGen and/or void the warranty. Important information essential to the installation and operation...

  • Page 9: The Whispergen

    PPS16 is capable of charging and managing a lead-acid battery bank to provide a DC electrical power supply. The WhisperGen PPS16 also provides heat energy in the form of hot coolant for space heating and domestic hot water generation. ELECTRICAL APPLIANCES ·...

  • Page 10: How It Works

    The burner consumes air and fuel. The flow rate of air and fuel into the burner is optimised by a microcomputer. This maximises combustion efficiency and minimises exhaust emissions. The microcomputer automatically controls all WhisperGen functions and displays real-time information about the system on a control panel from which the user can also alter operating options.

  • Page 11: Typical Marine Application

    Typical Marine Application How It Works Typical Marine Application Number Description WhisperGen Battery Bank DC/AC inverter Standard domestic appliances Hot water for domestic use Space heating Excess heat removal 12 or 24 V equipment Cool exhaust vent...

  • Page 12: Technical Specifications

    Technical Specifications How It Works Technical Specifications Feature Specification Remark Prime mover 4-cylinder Stirling-cycle Closed thermodynamic engine pressurised to 28 cycle. bar with nitrogen. Power output Co-generation of heat and electricity. Heat 5.5kW useable heat Heat output depends on (up to 6.5kW in heating operating conditions.
  • Page 13 Technical Specifications How It Works Feature Specification Remark Cooling system Cooling method Primary Cooling: Removes heat from High quality marine grade engine. glycol-based corrosion- inhibited anti-freeze for Heat is transferred to freezing conditions. hot water cylinder(s) Clean distilled water and high- and space heater(s).

  • Page 14: Summary Of Parts

    Summary of Parts How It Works Summary of Parts Personal Power Station STANDBY FAULT STARTING AUTOCHARGE RUNNING EXT CONTROL STOPPING HEAT MANAGE START STOP FUEL Number Description Fuel evaporator assembly Air intake Burner assembly Exhaust heat exchanger Lifting lug Terminal block Electronics enclosure Main enclosure (cover) Fuel valve...

  • Page 15: Control Panel Parts

    The arrow keys that provide access to system Keys menus for; (a) Information display; and (b) Editing system parameters. STOP Key The key that shuts down the WhisperGen Indicators The lights that indicate the status of the WhisperGen system. STANDBY: the WhisperGen is ready to start.

  • Page 16: Safety Precautions

    WhisperGen , cause personal injury, and/or void the warranty. This manual must be permanently placed alongside the WhisperGen maintained in a readable condition. Pe rs ona l Pow er St at ion F U E L...
  • Page 17 Do not use fuels other than the specified class of fuel as this may damage the WhisperGen and/or cause a fire Air bubbles present in the fuel line can cause the WhisperGen malfunction. Bleed the fuel line after filling a completely empty fuel tank.
  • Page 18 Safety Precautions How It Works The cooling system is vital to the performance of the WhisperGen . If there are leakages in the cooling circuit, or the water is not flowing, inform an authorised WhisperGen agent immediately. Use only the recommended coolant mixture. Using an incorrect type of...
  • Page 19 OF F Do not expose the WhisperGen to extreme temperatures. The ambient temperature should not exceed 40°C or fall below -10°C Personal Power Station FUEL Do not install, operate or store the WhisperGen in a wet or poorly ventilated place.
  • Page 20 P ersonal Pow er St at ion F UEL OF F Do not store rags or other items inside or beside the WhisperGen as the air circulation through the WhisperGen may be disrupted. P ersonal Pow er St at ion...
  • Page 21 P ersonal Pow er St at ion F UEL OF F In some countries, it is a requirement that a maintained fire extinguisher be permanently located alongside an installed WhisperGen . Consult your local authority for information. P ersonal Pow er St at ion...

  • Page 22: Operation

    Operation Introduction Operation Introduction This section outlines the procedure for operating your WhisperGen . It will show you how to: Start and stop the WhisperGen Charge the battery bank; Manage heat generation; Clear faults and warnings; Adjust the contrast of the LCD; and...

  • Page 23: Information Structure

    Operation Information Structure Information Structure The information displayed on the control panel is structured as shown below. For an explanation on how to navigate within this information structure, individual parameter meanings and edit settings refer the section entitled Displaying System Information. User Fault / Warning Extra Info...

  • Page 24: Starting The Whispergen

    – see section entitled Clearing Faults and Warnings. If nothing is displayed on the control panel, check that the WhisperGen is connected to the battery bank and that the 3A fuse (F2 position as marked on PCB) is not blown.
  • Page 25 The WhisperGen must be in the standby mode before it can be started. The WhisperGen must also be allowed to cool down before it can be restarted.

  • Page 26: Stopping The Whispergen

    "WhisperGen". The WhisperGen must be in the standby mode before it can be started again. If a remote switch has been installed to control the WhisperGen , you can also stop the WhisperGen with the remote switch, refer to section entitled Remote Controlling for more details.
  • Page 27 The flame in the WhisperGen burner will be extinguished within a few seconds. The fuel cut-off will be registered as a fault and the WhisperGen will stop. The fault will need to be cleared (see section entitled Clearing Faults and Warnings) before the WhisperGen can be started again.
  • Page 28 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 29: Remote Controlling

    To set the remote switch to start/stop the WhisperGen Access the User Menu on the control panel. Access the default display on the control panel by pressing Left Arrow repeatedly.
  • Page 30 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 31: Managing The Battery Bank

    The absorption and float charging voltages, the current level at which absorption-charging ceases, and other battery-charging settings, are set during the commissioning of the WhisperGen . These settings are set according to the needs of your particular application. If you wish to change these settings, contact your authorised WhisperGen agent.
  • Page 32 Optional: press Left Arrow repeatedly to return to the default display. The default display re-appears automatically after a few minutes of inactivity on the control panel. With the Auto-charge option turned ON, the WhisperGen will automatically start whenever the battery bank charge level falls below a preset level.
  • Page 33 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 34: Managing Heat Generation

    Managing Heat Generation Managing Heat Generation 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 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: Clearing Faults And Warnings

    Error messages associated with faults from which the WhisperGen cannot recover by itself need to be cleared before normal operation of the WhisperGen be resumed. To clear an error message: Physically correct the fault. Refer to the Trouble Shooting section for more information.
  • Page 37 If this occurs the WhisperGen will attempt to clear the fault and restart itself. The fault needs to be cleared before the WhisperGen can be started again. However, it is however recommended that you determine and correct the cause of the warning as soon as possible.

  • Page 38: Adjusting The Lcd

    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 39: Displaying System Information

    0 to 999,999 hours. since the WhisperGen was first commissioned. The WhisperGen must be serviced by an authorised WhisperGen agent every 12 months or every 500 hours of operating time, whichever comes first. # Of Starts The cumulative number of times the 0 to 999,999.
  • Page 40 Max Run Hours The number of hours of operation after which the 1 to 24 hours, or 25 hours WhisperGen is to stop. This parameter setting is a for continuous operation "timer" by which the WhisperGen operates – see (default).
  • Page 41 WhisperGen alternator. Positive 24V: -10 to 37A. values indicate current generation and negative values indicate current flow to the WhisperGen from the battery bank during cranking. Air % The power applied to the air blower as a 0 to 100%.
  • Page 42 The seawater and coolant bleeding function – see ON or OFF (default). section 3.8. Enable Starts The function that enables or disables WhisperGen 0 (default), 1 or 2. starts during maintenance or servicing. "0" = "no starts allowed"; "1" = "allow manual starts only"; "2"...

  • Page 43: Displaying Information

    Operation Displaying Information Displaying Information Information displayed on the control panel is structured as shown in the section entitled Quick Reference - Information Structure. The default display is the highest level on the information structure. If no keys are pressed for a few minutes, the control panel defaults to the last displayed parameter on the default display To access the default display at any time: Press Left Arrow repeatedly until one of the default display...

  • Page 44: Editing Parameter Settings

    Operation Editing Parameter Settings Editing Parameter Settings Information displayed on the control panel is structured as shown in section entitled Quick Reference. The settings of all the parameters under the User Menu and Installation Menu can be edited. The Warning Code Edit to clear parameter under the Fault/Warning Menu can also be edited.

  • Page 45: Maintenance

    If service checks are not performed by an authorised WhisperGen service agent every 12 months or 500 hours of operating time from the date of commissioning, the warranty on the WhisperGen will be void. When performing any maintenance work on the WhisperGen...

  • Page 46: Scheduled Service Intervals And Tasks

    Maintenance Scheduled service intervals and tasks Scheduled service intervals and tasks Service A – Minor Service Interval What to check after each 500 hours of use: Service A Schedule: Carry out Service A Tasks in the sequence listed below: 500 hours use 1.Check all coolant levels and flow rates.

  • Page 47: Removing The Enclosure Lid

    Maintenance Removing the Enclosure Lid Removing the Enclosure Lid The enclosure lid protects the internal parts of the WhisperGen and is held in place by two rubber rings. Some maintenance and troubleshooting procedures require the enclosure lid to be removed.

  • Page 48: Checking The Fuel

    Replace the fuel tank cap. If the fuel tank is empty and a fuel-related error message is displayed on the control panel, you will need to bleed the fuel line before the WhisperGen can be operated normally again. If you need to bleed the fuel line then see bleed the fuel system.

  • Page 49: Bleeding The Fuel Line

    Filling a fuel tank that has run empty may introduce air bubbles Overview into the fuel line that could cause the WhisperGen to malfunction. After filling an empty fuel tank, you must bleed the fuel line to remove any air bubbles that might be trapped in it.
  • Page 50 12. Reconnect the fuel line to the evaporator. 13. Finger tighten the nut against the shoulder. Using a spanner, tighten ¾ turn only. 14. Ensure that there is no leakage. 15. Replace the enclosure lid. The WhisperGen may now be started as required.

  • Page 51: Cleaning The Fuel Pump Filter

    Clean the fuel filter inside the fuel pump if faults related to fuel supply occur frequently or if the power output is constantly low. To clean the fuel filter: Procedure Turn off the fuel tank valve and the WhisperGen fuel valve. Fuel Pump...
  • Page 52 10. Bleed the fuel line. 11. Check that there is no fuel leakage. If there is another fuel filter installed external to the fuel pump, it should be cleaned also. Follow the instructions provided by the WhisperGen service agent who installed the external filter.

  • Page 53: Checking The Coolant

    If freezing conditions are expected, a marine-grade anti-freeze and corrosion inhibitor is to be used. All additives must be pre-mixed. Follow the dilution recommendation of the manufacturer. The cooling system of the WhisperGen is vital to its performance. If the coolant level is not maintained correctly, damage may occur.

  • Page 54: Bleeding The Coolant Circuit

    WhisperGen to malfunction. Should this occur, bleed the coolant circuit. To prevent unintentional starts of the WhisperGen , heed the warning given at the beginning of this section Do not touch the surfaces that are labelled as hot.
  • Page 55 You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel. 18. Replace the enclosure lid. The WhisperGen may now be started as required. The seawater circuit may need to be bled if the seawater pump inlet has been lifted above seawater level.

  • Page 56: 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.

  • Page 57: Replacing The Glow Plug

    The glow plug may be hot. Do not touch the wire coil on the new glow plug, as this will shorten its life span It is advisable to keep a spare glow plug with the WhisperGen at all times. Glow plugs used on the WhisperGen...

  • Page 58: Replacing Fuses

    Ensure that the replacement fuse is of a similar type (Ø0.25 x 1.25 inch, or Ø6.35 x 31.75mm) and of the correct current rating (2.00A). It is advisable to keep spare fuses with the WhisperGen at all times. To replace the battery bank voltage fuse: Procedure Unscrew the fuse holder.
  • Page 59 Do not touch surfaces that are labelled as hot Ensure that the replacement fuse is of a similar type and of the correct current rating. It is advisable to keep spare fuses with the WhisperGen at all times. To replace a fuse (other than the battery bank voltage fuse):...
  • Page 60 Replace the electronics enclosure cover and fasten the four screws. Replace the enclosure lid. Reconnect the WhisperGen to the battery bank by closing the circuit breaker. Note that WhisperGen fuses can be obtained from electrical hardware suppliers or your authorised WhisperGen service agent.

  • Page 61: Replacing The Fid

    Do not touch the surfaces that are labelled as hot. It is important not to twist the brass nut on the FID as this may damage the FID. It is advisable to keep a spare FID with the WhisperGen at all times.
  • Page 62 Maintenance Replacing the FID Insert a straight length of rigid wire vertically into the FID hole. The wire should go down 134 ± 5mm. Wire Evaporator WTL0041 With the wire touching the base of the FID hole, mark on the wire the top level of the evaporator.
  • Page 63 Twist the FID from side to side while pushing it straight down. 12. Fasten securely the FID clip to the evaporator, and the wire terminal to the FID. 13. Replace the enclosure lid. The WhisperGen may now be started as required.

  • Page 64: Replacing The Oxygen Sensor

    In general, you should check the FID for error codes 60, 61, and 62 before deciding to replace the oxygen sensor. To prevent unintentional starts of the WhisperGen , heed the warning given at the beginning of this section.
  • Page 65 Do Not Touch Here WTL0048 Finger tighten the nut that holds the oxygen sensor in place. Using a spanner tighten 1¼ turns only. Re-fit the electrical connector. Replace the enclosure lid. The WhisperGen may now be started as required.

  • Page 66: Replacing The Evaporator Wick

    You must remove the FID before you remove the evaporator. Removing the evaporator with the FID in place will damage the FID. Only replace the gasket with a genuine WhisperGen gasket. Do not use other gasket material. It is advisable to keep a spare evaporator wick with the WhisperGen at all times.
  • Page 67 17. Refit the FID. Carefully the procedure in this manual entitled Replacing the FID to ensure correct FID positioning for optimal running. 18. Replace the enclosure lid. 19. Turn on the WhisperGen fuel valve. The WhisperGen may now be started as required.

  • Page 68: Replacing The Evaporator

    It is advisable to keep a spare evaporator with the WhisperGen at all times. To replace the evaporator: Procedure Remove the FID. Remove the glow plug. Turn off the WhisperGen fuel valve. Personal Power Station FUEL Unscrew the fuel line fitting on top of the burner.
  • Page 69 Maintenance Replacing the Evaporator Undo the four screws on top of the evaporator. Evaporator (top view) Burner WTL0049 Lift the evaporator out of the burner. WTL0050 Place the evaporator gasket on the new evaporator, ensuring that all the holes line up. WTL0051 Insert the new evaporator with the gasket into the burner and secure the four screws.
  • Page 70 14. Bleed the fuel line. Refer to section entitled - Bleeding the Fuel Line. 15. Replace the enclosure lid. 16. Turn on the WhisperGen fuel valve. The WhisperGen may now be started as required. The old evaporator can be returned to your authorised WhisperGen service agent for servicing.

  • Page 71: Flushing The Exhaust Heat Exchanger

    Flushing the Exhaust Heat Exchanger Flushing the Exhaust Heat Exchanger Keep the exhaust heat exchanger free from blockages to ensure optimum Overview performance of the WhisperGen If the exhaust heat exchanger becomes blocked, the performance of the WhisperGen will decrease.

  • Page 72: Winterising The Whispergen

    , and you must also ensure that the secondary system is drained of all raw water. The fresh water is normally plumbed into the pressurised water supply to a fresh water connector on the WhisperGen Drain any water in the condensate trap and condensate drain. Do this for all condensate drains that may be in the exhaust system.

  • Page 73: Trouble Shooting

    If service checks are not performed by an authorised WhisperGen service agent every 12 months or 500 hours of operating time from the date of commissioning, the warranty on the WhisperGen will be void. When performing any maintenance work on the WhisperGen...
  • Page 74 FID and/or oxygen sensor replacement. For all WhisperGen faults and maintenance procedures not listed in this manual, please contact your authorised WhisperGen service agent for assistance. When maintaining or troubleshooting the WhisperGen , only perform the procedures recommended in this manual. If you perform other...

  • Page 75: Correcting Faults

    Likely Cause and Recommended Action Likely cause: Exh overtemp Low gas pressure and/or burner seal has failed. Recommended Action: Attempt to restart. Contact an authorised WhisperGen service agent if the problem reoccurs. Block overtemp Likely cause: Insufficient cooling of the engine block.
  • Page 76 Trouble Shooting Correcting Faults Likely cause: Isolator stuck on Abnormal electrical condition. Recommended Action: Attempt to restart. Contact an authorised WhisperGen service agent if the problem reoccurs. Low batt volts See 18. Glowplug cct fault Likely cause: Glow plug faulty and/or glow plug fuse blown.

  • Page 77: Correcting Warnings

    Low power output, possibly due to low gas pressure. Low fuel flow. Recommended Action: Check fuel level, fuel valve, and fuel filter. Check exhaust for blockage. Flush heat exchanger. Restart. If the problem reoccurs contact an authorised WhisperGen service agent. O2 sensor OOL Likely cause: Oxygen sensor reading out-of-limits, possibly resulting in poor combustion.
  • Page 78 Likely Cause and Recommended Action Likely cause: Exhaust gas hotter than normal, possibly due to low engine gas pressure. Recommended Action: Attempt to restart. Contact an authorised WhisperGen service agent if the problem reoccurs. Likely cause: Engine coolant hotter than normal.

  • Page 79: Resetting The Whispergen

    Due to unusual circumstances, the control panel may sometimes display an incoherent message. If this happens, the control panel should be reset. When performing trouble shooting tasks on the WhisperGen refer to the applicable sections(s) when removing or replacing parts.
  • Page 80 Unplug and then re-plug in the second fuse from the bottom - the fuse that has a current rating of 3A. WTL0053 Check that the WhisperGen is responsive to key presses on the control panel. If the control panel display was completely blank, it may be that the fuse was blown.

  • Page 81: Service Log

    Service Log Service Log (500 hour services) Service Log Service Log (500 hour services) Date / Hours Description of Work Done Agent's Stamp DD MM YY 500 Hour Meter Reading DD MM YY 1500 Hour Meter Reading DD MM YY 2500 Hour Meter Reading DD MM YY 3500 Hour Meter Reading...

  • Page 82: Service Log (1000 Hour Services)

    Service Log Service Log (1000 hour services) Service Log (1000 hour services) Date / Hours Description of Work Done Agent's Stamp DD MM YY 1000 Hour Meter Reading DD MM YY 3000 Hour Meter Reading DD MM YY 5000 Hour Meter Reading...

  • Page 83: Service Log (2000 Hour Services)

    Service Log Service Log (2000 hour services) Service Log (2000 hour services) Date / Hours Description of Work Done Agent's Stamp DD MM YY 2000 Hour Meter Reading DD MM YY 4000 Hour Meter Reading DD MM YY 6000 Hour Meter Reading...

  • Page 84: Compliance Information

    CE marked for applications where it is installed in European CE mark recreational craft. This means that in such an installation the WhisperGen complies with the Essential Health and Safety Requirements of the relevant European Commission Directives, which are: •...

This manual is also suitable for:

Pps16-12mdPps16-24md

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