Related Manuals for WhisperPower Piccolo Genverter
Summary of Contents for WhisperPower Piccolo Genverter
- Page 1 Installation Manual Marine Diesel Piccolo Genverter E n j o y G r e e n E n e r g y Piccolo GV 2 | 3 | 3+ Piccolo 8 | 10 | 12 | 15 | 18 whisperpower.com...
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Page 3: Table Of Contents
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 1 CONTENTS INTRODUCTION ������������������������������������������������������������������������������������������������������������������������� 5 USE OF THIS MANUAL VALIDITY OF THIS MANUAL INSTALLATION PARTS INSTALLATION ���������������������������������������������������������������������������������������������������������������������������� 5 GENERAL LOCATION PROTECTION AGAINST DIRT, SAND AND BAD WEATHER CONDITIONS SOUND AND VIBRATION REDUCTION 2.4.1 Further recommendations... - Page 4 INSTALLATION SUMMARY ���������������������������������������������������������������������������������������������������������16 GENERAL COMMISSIONING TABLE TECHNICAL DATA SPECIFICATION OF THE ACCESSORIES INSTALLATION MATERIALS DIAGRAMS & DRAWINGS ���������������������������������������������������������������������������������������������������������21 ELECTRICAL DIAGRAMS MECHANICAL DRAWINGS...
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Page 5: Introduction
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 1 INTRODUCTION WARNING A warning symbol draws attention to special warnings, instructions or procedures which, if not strictly 1�1 USE OF THIS MANUAL observed, may result in damage or destruction of equipment, severe personal injury or loss of life. This manual serves as a guideline for the safe and effective installation of the WhisperPower genverters for marine DANGER applications. This danger symbol refers to electric danger and It is obligatory that every person who is involved with the draws attention to special warnings, instructions or procedures which, if not strictly observed, may result installation of the genverter must be completely familiar with the in electrical shock which will result in severe personal contents of this manual, and that he/she carefully follows the injury or loss of life. -
Page 6: Protection Against Dirt, Sand And Bad Weather Conditions
2�4�1 Furtherrecommendations to remove air from the engine room. WhisperPower genverters are standard equipped with a sound In cases where it is impossible to meet the above mentioned cover canopy. This sound cover has been designed to give effec- temperature limit by using engine compartment ventilation, con- tive sound insulation. For optimum sound and vibration dampen- nections are to be made for an air inlet directly to the genverter ing, the following factors should be considered enclosure. With these connections the genverter can be directly Most importantly, the structure on which the genverter connected to an air duct. is placed must be stiff. Directly below the base frame, the structure should be supported by the vessel’s frames. When Air inlets should be louvered, where appropriate, to protect the this is not possible horizontal structures should be made engine room and to protect the genverter from water spray. stiff by additional provisions (Figure 1). In larger vessels a X = wrong, V = OK Fig.1:Mounting of the WhisperPower genverter... -
Page 7: Connections
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 2�6 CONNECTIONS The genverter comes with all supply lines and output cables (i.e. electric cables, exhaust stub, fuel lines etc.) already connected. The supply lines are fed through the capsule’s front base. The connections are marked as shown in Figure 2 - 4 . Refer to Section 5.1 for a graphical overview of installation and wiring connection requirements. 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! Beforeworkingonthesystem,readthesafety instructions. 1 Exhaust Marine: ø40 hose connection 2 To expansion tank 3 AC Power 5G6 4 AC Sense 4G2.5... -
Page 8: Fuel Supply
Fig.5: Fuel tank below the genverter 1 Exhaust Marine: ø40 hose connection 2 To expansion tank 3 AC Power 5G6 4 AC Sense 4G2.5 5 Water in (cold) hose 20 mm 6 Fuel out 8mm Fig.6: Fuel tank above the genverter 7 Fuel in 8mm 2�7�2 Fuelliftpump 8 Battery + “Red”... -
Page 9: Fuel Filters
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 drained into the tank when the engine is stopped because air cannot there is enough liquid initially. enter into the return line, thus avoiding starting trouble. This has to be checked when commissioning the generator set. Both supply and return fuel pipe lines should be made of appropri- By filling up the expansion tank when necessary there will always ate material and have an 8 mm inner diameter. The quality of the be enough liquid in the system. The hose that is in the delivery tubing of fuel pipes may be subject to local regulations depending on has to be connected to the connection on the side of the filling the application of the vessel. cap. This is a non-kinking hose made of heat resistant plastic. The fuel pipes can be connected to the flexible hoses which are on The hose passes through a hole in the base. the genverter and are prepared to be fitted to 8 mm pipe. The result- ing fuel line complies with CE standards as well as ISO 7840 A2. MAX. 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 (i.e. bypassing the top), the back- pressure may be too high. - Page 10 WRONG! leadstoimmediateengineproblemsandpossibly severedamage! DAMAGECAUSEDBYTHEINGRESSOFWATERINTHEENGINEIS NOTCOVEREDBYGUARANTEE. The siphon breaker that is delivered with the Whisper Power siphon breaker installation kit does not require a connection for a Fig.9: Installing the water intake hose to drain the little water that could be spilled from the valve. If you use another kind of siphon breaker that has a hose connec- On motorboats and on sailing boats the water scoop for a gen- tion, make sure that the drain should go downwards directly and erating set should be fitted with the opening faced backwards to that it may not end under water (refer to Figure 11). prevent water being forced in during sailing. OPEN 2�8�4�3 Waterstrainer Use an appropriate water strainer with connections of well accessible position, 5 cm above the waterline (see water inlet kit item 7). 2�8�4�4 Siphonbreaker(airvent) When the point of water injection is below the waterline, then Fig.11: Wrong siphon breaker hose routing – when the engine is stopped – there is a risk that the cooling (non-WhisperPower siphon breaker) water may enter the engine as a result of siphoning. To avoid this,...
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Page 11: Wet Exhaust System
The exhaust hose descends from the capsule to the water lock. If the through-hull exhaust outlet has to be mounted far from the Then the hose rises via the “goose neck” to the through-hull generating set (i.e. the length of the exhaust piping from the gen- exhaust outlet, situated minimum 50 mm above the water line erator to the top of the goose neck (water separator) exceeds 3 (Figure 12, ref 5). The “goose neck” must be vertical and situated m; see Figure 14), an exhaust/water separator must definitely be preferable along the ship’s keel centre line. If the generating set installed. The sea water from the separator must then run down is mounted less than 600 mm (24”) above the waterline, a “goose along the shortest possible path to the through-hull outlet. Only neck” must be installed to prevent the engine from overflowing. after the exhaust/water separator the exhaust hose may have a It is recommended to install an extra muffler (Figure 12, ref 2) length of over 7,5 m (Figure 14). close to the through-hull fitting. However, water traps should be avoided as the fumes still contain water and this should not accumulate in bends (see Becauseofthesmallgasflowofthesmallengine, itisveryimportanttokeepstrictlytotheinstruc- Figure 15). An additional outlet exhaust muffler close to the hull tionsabove.Somemufflersandwaterlockscause outlet will help further to reduce noise emission (Figure 12, ref 2). toohighbackpressure.Youareadvisedtousea WhisperPowerinstallationkitorchecktheback pressure.Toohighbackpressurecausesthe systemtofillupwithwaterthataffectstheoutlet valveandvalveseat. Fig.13: Super silent exhaust system... - Page 12 Fig.14: Install the water lock close to the generator (Hoses Piccolo 18 ø50mm) Fig.15: Water trap in exhaust system When Installing the skin passage for the exhaust gas take care that the exhaust gas flow does not touch the water surface. This can cause a lot of noise. (see Figure 16) Donotaimtheexhaustgasflowdirectlyatthewatersurface. WRONG! Fig.16: Outlet direction...
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Page 13: Electrical Installation
The standard electrical control system is in 12 Volt with negative (Figure 18). earth. Non-earth return is available as an option. The engine is controlled by a highly advanced microprocessor based system: Digital Diesel Control, which has both a local control and a remote panel. 3�1�2 Remotecontrol A remote control panel also containing a microprocessor is included in the delivery, as well as a 10 m 8-pole communication cable (Figure 17). Other lengths are available on request. A longer (up to 30 m) cable can be connected if required. For distanc- es exceeding 30 m, please consult the WhisperPower service department. Fig.18: Remote box terminals 3�1�4 Connectionforemergencystop/firealarmswitch Fig.17: Remote control cable Fig.19: Connection for emergency stop / fire alarm switch The control panel can be mounted in the dashboard using the plastic sawing template. For dimensions, refer to the drawings in To connect an emergency stop button or to stop the generator Chapter 5. automatically in case of a fire alarm, you can use the bypass con-... -
Page 14: Automatic Starting And Stopping
3�1�5 Automaticstartingandstopping Another possibility is to monitor the voltage of a second battery (not being the starter battery) and to start the genverter auto- 3�1�6 General matically when this voltage drops below a set value. This second battery is often called “auxiliary battery” or “service battery”. It is referred to as BAT2 in the DDC menus. A sense wire to monitor WhisperPower cannot be held responsible for dam- the second battery should be connected (check polarity!) to age caused by the genverter running unattended the connector on the back of the remote panel (Figure 18). The using the auto-start/stop mode or interval mode sense wires must be connected directly to the second battery and be protected by a 3A fuse Using the auto-start/stop or interval mode, the genverter may start unexpectedly. When working on Settings: For settings other than the factory settings, refer to the the electrical system, the 3 Amp fuse must be DDC user’s manual, especially to the APPENDIX. removed from the control panel and the battery plus cable must be removed from the battery 3�1�8 STARTERBATTERY Included in the delivery are warning stickers to be applied on several parts of the electric installation For starting, the genverter requires a 12V starter battery of 80 (transfer switch, distribution box, etc.) to warn against possible automatic starting of the genverter. The genverter can be connected to the main engine battery or have its own battery. We strongly recommend the use of a sepa- The WhisperPower Digital Diesel Control system offers several rate battery for the genverter and keeping the wiring system for options for automatic starting and stopping. This menu as well as the main engine and the domestic DC supply system completely other DDC menus may be locked. For unlocking and setting these separate and individually connected to separate batteries. -
Page 15: Other Recommendations And Warnings
3�3 ALTERNATING CURRENT For safety reasons connect the main ships ground to the negative DANGER of the generating set start battery. However, when a ungrounded DC system or positive grounded DC system is applied the battery Theelectricpowersuppliedbythegenverterisof negative should not be connected to the main ships ground. ahighvoltageanddangeroustopeople.Before workingonthesystemreadthesectionsonsafety 3�6 CABLE intheusersmanual. For the power cable we recommend the use of 3 wire oil resis- tant cable with a sufficient cross sectional area. For long cables it Generatorsusedonvesselsthatareoperatedina is recommended to apply cables with a larger cross section (refer hazardousenvironmentoftenhavetofulfilspecial regulationsandadditionalmeasureshavetobe to ISO 13297, Annex A). takenaccordingly These genverters are designed to generate power for both AC and DC installations, depending on the type of WhisperPower PowerCube or Power Module installed with the genverter. Be sure that all electrical installations (including all safety systems) comply with all regulations required by the local authorities. All electrical safety/shutdown and circuit breaking systems have to be installed on-board as the genverter itself cannot be equipped with such equipment for every possible variation. The vessel’s power supply system should be suitable and safe for the voltages applied and the power that will be generated. Spe- cial attention has to be paid on dividing the system in branches which are fused individually. -
Page 16: Installation Summary
(max. 14.5 V). Connect exhaust system. Close the sound shield and check the noise level. Connect ‘fuel supply line’ to the water separator/ fuel filter. S top the genverter and check the engine again for leakages Connect ‘fuel return line’ to the fuel tank. of oil, fuel or coolant and check the oil level again. Connect remote panel (just plug in). 4�3 TECHNICAL DATA Connect the AC cables to the PMG/DC PowerCube. C onnect the battery cables to the 12V starter battery Refer to the User’s Manual for an overview of general technical positive and negative terminals. specifications. Install a WhisperPower battery charger (optional). 4�2 COMMISSIONINGTABLE 4�4 SPECIFICATION OF THE ACCESSORIES Check if the air inlet is sufficient. Item SizeonPiccolo8 SizeonPiccolo18 andPiccolo10 C heck if the cooling system for the engine is properly Water pickup scoop 1/2” = 19 mm 1/2” = 19 mm installed and properly filled with G12+ cooling liquid . Inlet valve 1/2” in / 19 mm out... -
Page 17: Installation Materials
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 4�5 INSTALLATION MATERIALS WATER INLET KIT Number Quantity Articleno Description Dimensions 50230052 Water pickup scoop ¾” Lever operated ball 50230042 ¾” valve f/f 50221004 Male hose connector ¾” × 20 mm 50221503 Hose clamp, stainless 19-29 mm... - Page 18 WATERSEPARATORANDWETEXHAUSTKITS(40mm) According to ABYC recommendations all hose connections should be made using double clamps. Maximum torque for hose clamps: 6.0Nm Articleno Description Dimensions Number Quantity 50230038 Brass through hull fitting hose connection 1 1-4 x 40 50220033 Marine exhaust hose 40 mm (1 5-8 inch) 50220033 Marine exhaust hose 40 mm (1 5-8 inch) 50220033 Marine exhaust hose 40 mm (1 5-8 inch) 50230033 Brass through hull fitting 1 1-4 x 70 50230044 Lever operated ball valve FF 1 1-4...
- Page 19 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 WATERSEPARATORANDWETEXHAUSTKITS(51mm) According to ABYC recommendations all hose connections should be made using double clamps. Maximum torque hose clamps: 6.0Nm / 54 lnLbs Number Quantity Articleno...
- Page 20 FUEL KIT Number Quantity Articleno Description Dimensions 50230091 Filter head for fuel strainer/water M14x1.5 mm separator 50221618 Parallel male coupling M14 - 8 mm 50221619 Parallel male coupling M14 - 10 mm 50221620 Hose connection, outer cone M16 × 1.5 mm, 8 mm 50230092 Filter for fuel strainer/water separator 50221522 Hose clamp, stainless 10-16 mm 50221632 Gasket ring 18 × 14 × 1.5 mm not shown 50221203 Straight coupling 8 mm not shown 50221252 Barbed-smooth hose nipple...
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Page 21: Diagrams & Drawings
Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 5 DIAGRAMS & DRAWINGS 5�1 ELECTRICAL DIAGRAMS Fig.22: Layout of Piccolo 8 genverter system... - Page 22 Fig.23: Layout of DC generator system featuring Piccolo 2 and DC PowerCube...
- Page 23 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 Fig.24: Layout of Piccolo 10 genverter system...
- Page 24 Fig.25: Layout of Piccolo 3, 15 Genverter system.
- Page 25 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 Fig.26: Layout of DC generator system featuring Piccolo 10 and two DC PowerCubes...
- Page 26 Fig.27: Layout of DC generator system featuring Piccolo 3 and two DC PowerCubes...
- Page 27 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18...
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Page 29: Mechanical Drawings
5�2 MECHANICAL DRAWINGS 1 Exhaust Marine: ø40 hose connection 13 (8x) 16 V-belt 2 To expansion tank 17 Accelerator 3 AC Power 4G4 18 Stop solenoid 4 AC Sense 4G2.5 19 Oil dipstick 5 Water in (cold) hose 20 mm 20 Oil Filter 6 Fuel out 8mm A. - Page 30 1 Exhaust Marine: ø40 hose connection 16 V-belt 17 Accelerator 2 To expansion tank 13 (8x) 3 AC Power 4G4 18 Stop solenoid 4 AC Sense 4G2.5 19 Oil dipstick 5 Water in (cold) hose 20 mm 20 Oil Filter 6 Fuel out 8mm 21 Dynamo A.
- Page 31 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18 16 V-belt 1 Exhaust Marine: ø40 hose connection 17 Accelerator 2 To expansion tank 18 Stop solenoid 3 AC Power 5G6 19 Oil dipstick 4 AC Sense 4G2.5 20 Oil Filter...
- Page 32 5�3 1 Fuel out 8mm 16 V-belt 2 Water IN (cold) hose 20mm 17 Accelerator 3 Fuel IN 8mm 18 Stop solenoid 4 Syphon in/out 20mm 19 Oil dipstick 5 Exhaust Marine: ø50 hose connection 20 Oil filter 13 (8x) 6 Battery + "Red"...
- Page 33 Piccolo Marine Diesel Genverter 2 | 3 | 3+ | 8 | 10 | 12 | 15 | 18...
- Page 36 E n j o y G r e e n E n e r g y WhisperPower BV Kelvinlaan 82, 9207 JB Drachten The Netherlands www.whisperpower.com sales@whisperpower.com...
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