Whisper Power W-SQ Pro Installation Manual
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Whisper Power W-SQ Pro Installation Manual

Mobile diesel generator
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Installation Manual
Mobile Diesel Generator
W-SQ Pro
E n j o y G r e e n E n e r g y
15 kVA | 18 kVA | 1800 RPM | 240/120 V | 60Hz | Split Phase
whisperpower.com

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  • Page 1 Installation Manual Mobile Diesel Generator W-SQ Pro E n j o y G r e e n E n e r g y 15 kVA | 18 kVA | 1800 RPM | 240/120 V | 60Hz | Split Phase whisperpower.com...
  • Page 2 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator...

  • Page 3: Table Of Contents

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator CONTENTS INTRODUCTION ����������������������������������������������������������������������������������������������������������������������������������������������������������������4 GENERAL GENERATING SETS FOR MOBILE/LAND APPLICATIONS INSTALLATION ������������������������������������������������������������������������������������������������������������������������������������������������������������������5 GENERAL LOCATION INSTRUCTIONS FOR OPTIMAL SOUND AND VIBRATION INSULATION 2.3.1 Further recommendations VENTILATION CONNECTIONS 2.5.1 Fuel supply 2.5.2 Radiator cooling 2.5.3 Dry exhaust system 2.5.4...

  • Page 4: Introduction

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 1 INTRODUCTION The exhaust is of the dry type and includes a stainless flexible bellow and high quality mufflers. 1�1 GENERAL This installation manual applies to the installation of Whisper gensets in mobile/land applications. This manual is valid for the following models. Model Description 240-120V / 60 Hz W-SQ-Pro 15 Split phase, 1800rpm, Mobile 240-120V / 60 Hz, W-SQ-Pro 18 Split phase, 1800rpm, Mobile 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, Figure 1: Typical mobile/land applications radiator side noise levels, vibration, etc. the instructions set out in this manual...

  • Page 5: Installation

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 2 INSTALLATION Figure 4: Schematic installation diagram 2�3 INSTRUCTIONS FOR OPTIMAL SOUND AND 2�1 GENERAL VIBRATION INSULATION To ensure reliability and durability of the equipment, it is very Position the generating set as low as possible in the vehicle. The important that the installation is carried out with the utmost care generating set is secured to the base frame by means of flexible and attention. To avoid problems, such as temperature problems, engine mountings. This frame is mounted in the vehicle with noise levels, vibration, etc. the instructions set out in this manual additional vibration dampers. must be followed and all installation work must be carried out professionally. When it is possible to mount the unit directly on the chassis of the vehicle this has advantages in preventing vibrations by resonance. 2�2 LOCATION 2�3�1 FURTHER RECOMMENDATIONS...

  • Page 6: Ventilation

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 2�4 VENTILATION 2�5 CONNECTIONS The generating set normally draws air from the engine compart- The generating set comes with all supply lines and output cables ment. Engine compartment with natural ventilation must have (i.e. electric cables, coolant connections, exhaust, fuel lines etc.) vent openings of adequate size and location to enable the gener- already connected to the engine and generator. The supply lines ating set to operate without overheating. To allow Sufficient air are fed through the capsule’s front base. The connections are within the temperature limits of the generating set an opening of marked as shown in figures 7 till 10. at least 100 cm2 is required. A “sealed” engine compartment must have a good extraction ventilator to maintain reasonable ambient temperatures. High All electrical connections, cable types and sizes must comply with temperature of intake air reduces engine performance and the appropriate national regulations. Supplied cables are rated increases engine coolant temperatures. The rated power of for ambient temperatures up to 70°C. If the cables are required the generator is measured at an ambient temperature of 25°C, to meet higher temperature requirements, they must be run each temperature increase of 5°C reduces the engine power by through insulations. about 2%. In order to minimize these effects to the extent that the operator can influence them, the temperature of the engine ATTENTION! compartment must not exceed the temperature of the outside air by more than 15ºC.
  • Page 7 05 Communication cable 06 AC cable 3G 16mm² (1phase) AC cable 4G 10mm² (2phas) 07 Earth lug M10 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 08 Fuel out 8mm 09 Fuel in 8mm 10 Cooling water out hose 3/4"...

  • Page 8: Fuel Supply

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Figure 7: Fuel supply Fuel return Fuel supply Prefilter / Water separator (optional) Fuel Tank Figure 8: Fuel supply Fuel return Fuel supply Prefilter / Water separator (optional) Extra fuel lift pump (optional) Fuel tank Figure 9: Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle...

  • Page 9: Radiator Cooling

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator FUEL PIPES When the tank is above the generating set (figure 7) we recom- mend 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 gen- erating 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 ma- terial and 8 mm inner diameter tubing. The quality of the tubing of fuel pipes could be submitted to local regulations depending Figure 10: Ventilating an air trap on the application of the vehicle. Special attention should be paid to the ventilation of the systems. The fuel pipes can be plumbed to the flexible hoses which are Each installation system is standard supplied with an expansion on the generating set and have a connection to fit to 8 mm pipe. tank for the coolant, which is also used to release air bubbles and This fuel lines fulfils CE standards and are according to ISO 7840 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. It is important to avoid bends in the pipes, as they could trap air bubbles. The return pipe should never be connected to the...
  • Page 10 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator HOW AND WHERE TO MOUNT THE RADIATOR The expansion tank must be fitted in the outlet of the The radiator kit includes rubber mountings to prevent vibrations radiator = the inlet pipe of the engine to be transferred to the body of the vehicle (fig. 14). Due to the difference between vehicles general instructions are not avail- able. One has to find out where the best place for mounting is. For OEM customers WhisperPower can supply a special custom- ised installation kit.

  • Page 11: Dry Exhaust System

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator have the radiators vertically mounted on the roof. Note that the expansion tank should be above the radiator. When having the radiator horizontally mounted on the roof (refer to figure 18) 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 16: Making use of the space below the floor to get an optimal flow of air through the radiator Side mounted radiator...

  • Page 12: Electrical Installation (12 Volt)

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator consider proper guiding of 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 exhaust fumes going into the compartment. 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 muf- flers could be on the roof or one of them or both could be below the vehicle. Figure 20: Ways to prevent water to get in In general it is better to have the mufflers wide apart: the reso- A negative feature of a dry exhaust system is the heat radiated by nance muffler close to the generator and the absorption muffler its components. Measures are taken to overcome the heat prob- on the end of the line. A short pipe (30cm) should be on the far lem: The exhaust bent to bring the exhaust out of the canopy is end after the absorption muffler. The absorption muffler has no cooled by water. Insulation blankets are included in the exhaust...
  • Page 13 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator The “DDC black box” containing the microprocessor is located in the generator control cabinet. A local control panel is on the generating set. Remote control In order to enable remote start/stop sequences, display gener- ator information and many other functions the remote control panel containing a microprocessor has so be connected to the generator set. Within the standard delivery a 15m “straight” data cable is supplied. WhisperPower advises is not to exceed 30m / 100ft. Figure 23: Remote box terminals Acoustic alarm or warning lamp One can connect an external relay to generate an acoustic warning or applying a warning lamp etc. This output can supply max 150mA. Be aware of polarity as some relays has a integrated diode and should be connected plus to plus en minus to minus as indicated. Refer to fig. 23. To connect an emergency stop button or to stop the generator automatically in case of a fire alarm, you can use the bypass con- Figure 22: Remote control cable nection between fastons J7 and J18 on the backside of the local control panel. See fig. 24. To do so, remove this bypass connec-...
  • Page 14 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Automatic starting and stopping The generating set can be connected with the main engine bat- Whisper Power cannot be held responsible for tery or have its own battery. damage caused by the unattended running generator using the auto-start/stop mode or interval mode. We strongly recommend the use of a separate battery for the generating set and to keep the wiring system for the vehicle Using the auto-start/stop (interval) mode the engine and the domestic DC supply system completely separate generator can start unexpectedly.

  • Page 15: Ac Power System (120 / 240 Volt)

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator FUSE When two batteries are used in series to provide a 24 Volt supply system, never take off 12 Volt (starting) Output fuses (between the generating set and the electrical power from one of these batteries. This will result in installation) should be installed to protect the installed electrical severe damage to both batteries within a short time.

  • Page 16: Installation Specifications

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 3 INSTALLATION SPECIFICATIONS 3�2 COMMISSION TABLE C heck if a hole for combustion air intake is in the sound shield. Also check if an air inlet filter for combustion air is 3�1 GENERAL necessary and has been installed M ake a hole for combustion air in the sound shield. Mount an air inlet filter (if required) C heck if the cooling system for the engine is properly installed. Note that air traps must be avoided. M ount the generating set directly, without additional vibra- tion dampers, on a solid surface. C heck if the exhaust system is properly installed. Check maximum length of exhaust hose, diameter of exhaust M ount the cooling system for the engine piping. C onnect exhaust system. C heck all coolant connections.

  • Page 17: Technical Data

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 3�3 TECHNICAL DATA W-SQ- PRO 15 W-SQ- PRO 18 Split Phase Split Phase for mobile applications for mobile applications GENERAL Dimensions (l x w x h) 1145 x 625 x 690 mm 1220 x 719 x 754 mm Weight including sound shield 410 kg 495 kg Weight without sound shield 370 kg 455 kg Max. operation angle 20°...
  • Page 18 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator BATTERY INSTALLATION KIT <100 Ah Art. Nr. 40290106 Article No Description 61112007 WBC Handy 70 charger 12V – 7A 40290094 Battery terminal PLUS 40290093 Battery terminal MINUS 40290091 Terminal Cover RED (pos+) 40290092 Terminal Cover BLACK (neg-) 50214701 WP-Compact Manual Battery Switch 300A, single circuit ON-OFF 40290097 Battery pole adapter M6 BATTERY INSTALLATION KIT <100 Ah Art. Nr. 40290108...
  • Page 19 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Yellow Locite 577 1100 FUELFILTER 50209030 FUELFILTER 40209030 Fuel hose 16x8 L=200 50220063 50220063 Facet Fuel Pump 12V Electric 1000A195545 50201168 FUEL SUPPLY KIT Check valve fuel 8mm -421-99-0000- 1000P184653 50201164...
  • Page 20 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator DRY EXHAUST KIT 1½” Article No Description 50220043 Exhaust hose SS 1½" 500mm m/f 50220042 Insul. blanket 52X26 exhaust hose 50230523 Absorption muffler steel 1½" 50230524 Resonance muffler steel 1½" 50230525 Insulation blanket 70X55 muffler SDHC 1½" 50221403 Pipe nipple 1½"x300mm galvanized 50221423 Parallel male coupling 1½" galvanized 50221413 Straight coupling f/f 1½" galvanized 50221663 U-clamp 48 mm M10 50221664 Bracket U-clamp 25cm 48-60 mm passivated 50211406 Washer SP M10 50211447 Washer spring SP M10...
  • Page 21 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator RADIATOR COOLER KIT ENGINE 1¼” (AP430/2-230V) Article No Description 50230311 Radiator AP 430/2 230V 50221502 Hose clamp stainless 22-30 mm 50221064 Male nipple 1" 50221044 TEE fitting 1" 50221014 Male hose connection 1"x35 50221103 Straight reducer m/f 1”-¾" 50221004 Male hose connection ¾”x20mm 50212409 Temperature switch 87-82 degr 50201121 Vibration mounting 30x25mm 50211152...
  • Page 22 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Article No Description 50200017 Hose I.D. 25mm 0,3 meter 50221025 Hose connector M 1"x25" 50221014 Hose connector F 1"x35 50221503 Hose Clamp Stainless Steel 35mm TOTAL 40230655 Adjust kit 25mm to 35mm Generator to Radiator...

  • Page 23: Diagrams & Drawings

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4 DIAGRAMS & DRAWINGS 4�1 WIRING COLOURS W-SQ- PRO 15 SPLIT PHASE 60 HZ – MOBILE Wire number Origin Destination Section Color code - M1:+ -G3:+ 10 (mm²) -M1:+ 35 (mm²) -M1:+ -J1:+ 6 (mm²)

  • Page 24: Wiring Colours W-Sq- Pro 18 Split Phase 60 Hz - Mobile

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4�2 WIRING COLOURS W-SQ- PRO 18 SPLIT PHASE 60 HZ – MOBILE Wire number Origin Destination Section Color code -G1:BL - EXC - -J4:F- 1.5 (mm²) -G1:YL - EXC + -J4:F+ 1.5 (mm²) - G1:GN -J4:L1 1.5 (mm²)

  • Page 25: Layout Generator Control W-Sq- Pro 15 240/120Vac 60 Hz Split Phase 4-Wire

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4�3 LAYOUT GENERATOR CONTROL W-SQ- PRO 15 240/120VAC 60 HZ SPLIT PHASE 4-WIRE Figure 26: Layout generator control for W-SQ- PRO 15 Split Phase – Mobile...
  • Page 26 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Figure 27: Layout generator control for W-SQ- PRO 15 Split Phase – Mobile...
  • Page 27 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Figure 28: Layout generator control for W-SQ- PRO 15 Split Phase – Mobile...

  • Page 28: Wiring Colours W-Sq- Pro 18 Split Phase 60 Hz - Mobile

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4�4 WIRING COLOURS W-SQ- PRO 18 SPLIT PHASE 60 HZ – MOBILE Figure 29: Layout generator control for W-SQ- PRO 18 Split Phase – Mobile...
  • Page 29 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Figure 30: Layout generator control for W-SQ- PRO 18 Split Phase – Mobile...
  • Page 30 W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator Figure 31: Layout generator control for W-SQ- PRO 18 Split Phase – Mobile...

  • Page 31: Whisperpower Remote Panel

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4�5 WHISPERPOWER REMOTE PANEL Figure 32: WhisperPower remote panel The remote panel comes in a carton that can be used as a template to drill the mounting hole.

  • Page 32: W-Sq 15 Dimensions And Footprint (With Ddc Control)

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator 4�6 W-SQ 15 DIMENSIONS AND FOOTPRINT (WITH DDC CONTROL) Figure 33: Outer dimensions (mm) W-SQ- PRO 15 W-SQ- PRO 15 CONNECTIONS BOX DIMENSIONS • Exhaust: 1 ½” • Length: 1145 mm •...

  • Page 33: W-Sq 18 Dimensions And Footprint

    W-SQ PRO 15/18 kVA 60 Hz Mobile Diesel Generator W-SQ 18 DIMENSIONS AND FOOTPRINT Figure 34: Outer dimensions (mm) W-SQ- PRO 18 W-SQ- PRO 18 CONNECTIONS BOX DIMENSIONS • Exhaust: 1 ½” • Length: 1220 mm • Fuel hose: 5/16” (8 mm) •...
  • 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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