Whisper Power W-GV 4 Scalino Manuals

V1.1, April 2017 INSTALLATION MANUAL W-GV 4 Scalino genverter OUTDOOR for mobile and land-based use WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel. : +31-512-571550 Fax : +31-512-571599 www.whisperpower.com Art.nr. 40200845 CONTENTS 2 W-GV4 Scalino outdoor — April 2017 — EN CONTENTS 1 INTRODUCTION .......................................................................................................................................................................... 3 1.1 Use of this manual ................................................................................................................................................................ 3 1.2 Validity of this manual .......................................................................................................................................................... 3 1.3 Installation parts ................................................................................................................................................................... 3 1.4 Genverters on vehicles ......................................................................................................................................................... 3 2 INSTALLATION ............................................................................................................................................................................ 4 2.1 General ................................................................................................................................................................................. 4 2.2 Location ................................................................................................................................................................................ 4 2.3 Protection against dirt, sand and bad weather conditions ................................................................................................... 4 2.4 Sound and vibration reduction ............................................................................................................................................. 4 2.4.1 Further recommendations ................................................................................................................................. 4 2.5 Ventilation ............................................................................................................................................................................ 5 2.6 Connections .......................................................................................................................................................................... 5 2.7 Fuel supply............................................................................................................................................................................ 5 2.7.1 Fuel tank ............................................................................................................................................................ 5 2.7.2 Fuel lift pump ..................................................................................................................................................... 6 2.7.3 Fuel pipes ........................................................................................................................................................... 6 2.7.4 Fuel filters .......................................................................................................................................................... 6 2.8 Radiator cooling ................................................................................................................................................................... 6 2.8.1 General instructions........................................................................................................................................... 6 2.8.2 How and where to mount the radiator .............................................................................................................. 6 2.8.3 Bottom-mounted radiator ................................................................................................................................. 6 2.8.4 Side-mounted radiators ..................................................................................................................................... 7 2.8.5 Roof-mounted radiators .................................................................................................................................... 7 2.9 Dry exhaust system .............................................................................................................................................................. 7 2.9.1 General remarks ................................................................................................................................................ 7 2.9.2 The standard dry exhaust system ...................................................................................................................... 8 2.9.3 Installation of the exhaust ................................................................................................................................. 8 3 ELECTRICAL INSTALLATION ......................................................................................................................................................... 9 3.1 Engine control system .......................................................................................................................................................... 9 3.2 Starter battery ...................................................................................................................................................................... 9 3.3 Other recommendations and warnings ................................................................................................................................ 9 3.4 Alternating current ............................................................................................................................................................... 9 3.5 Cable protection (fuses) ....................................................................................................................................................... 9 3.6 Grounding ............................................................................................................................................................................. 9 3.7 Cable ................................................................................................................................................................................... 10 3.8 Connecting the Power Module ........................................................................................................................................... 10 4 INSTALLATION SUMMARY ........................................................................................................................................................ 11 4.1 General ............................................................................................................................................................................... 11 4.2 Commissioning table .......................................................................................................................................................... 11 4.3 Technical data .................................................................................................................................................................... 11 4.4 Specification of the accessoiries ......................................................................................................................................... 11 4.5 Fuel kit ................................................................................................................................................................................ 12 4.6 Battery installation kit ........................................................................................................................................................ 12 4.7 Exhaust kits ......................................................................................................................................................................... 13 4.7.1 Compact exhaust kit using combined muffler ................................................................................................. 13 4.7.2 Traditional exhaust kit using separate absorption and resonance mufflers .................................................... 14 4.8 12VDC radiator kit .............................................................................................................................................................. 15 5 DIAGRAMS & DRAWINGS ......................................................................................................................................................... 16 5.1 System diagrams ................................................................................................................................................................ 16 5.2 Mechanical drawings .......................................................................................................................................................... 17 INTRODUCTION 3 W-GV4 Scalino outdoor — April 2017 — EN 1 INTRODUCTION 1.1 USE OF THIS MANUAL This manual serves as a guideline for the safe and effective installation of the WhisperPower single-cylinder genverters for mobile applications. It is obligatory that every person who is involved with the installation of the genverter must be completely familiar with the contents of this manual, and that he/she carefully follows the instructions contained herein. 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, noise levels, vibration, etc. the instructions set out in this manual must be followed and all installation work must be carried out only by qualified, authorized and trained personnel, consistent with the locally applicable standards and taking into consideration the safety guidelines and measures (Chapter 2 of the user’s manual). The information, specifications, illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press. Our policy is one of continued development and we re-serve the right to amend any technical information without prior notice. Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer, distributor, or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof. Keep this manual in a secure place! 1.2 VALIDITY OF THIS MANUAL All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the single cylinder genverters delivered by WhisperPower. This manual is valid for the following models: Refer to the user’s manual for identification of the generator set. For other models see our website: www.whisperpower.com. WARNING! During installation and commissioning of the genverter, the Safety Guidelines & Measures are applicable at all times. See Chapter 2 of the user’s manual. WARNING! A warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment, severe personal injury or loss of life. DANGER! This danger symbol refers to electric danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in electrical shock with possibly severe personal injury or loss of life. WARNING! Before working on the system read the safety instructions in the user’s manual. 1.3 INSTALLATION PARTS Besides the parts that are included with the delivery you need at least the parts listed in 4.4 to install the genverter. Please note that this listing may not be complete, as every installation differs from the other. Oil is not included in the supply. Refer to the user’s manual for the right specifications. 1.4 GENVERTERS ON VEHICLES On vehicles the engine is cooled by an external radiator with an electric driven fan. The fan can mounted be in the side or on top of the vehicle, or below it. The exhausts recommended by WhisperPower are of the dry type and include a stainless steel flexible bellow and high quality mufflers. The exhaust can be below, in the side or on top of the vehicle, too. IT IS VERY IMPORTANT TO EVALUATE ALL PRO’S AND CONT’S BEFORE MAKING A CHOICE HOW TO SET UP THE INSTALLATION. Part no. Description 49012020 single-cylinder genverter (WP1) for outdoor use in mobile and land-based installations

USER’S MANUAL W-GV 4 Scalino genverter OUTDOOR for mobile and land-based use V1, April 2017 WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel.: +31-512-571550 Fax: +31-512-571599 www.whisperpower.com Art.no. 40200841 CONTENTS 2 W-GV4 Scalino outdoor — April 2017 — EN Contents 1 INTRODUCTION .......................................................................................................................................................................... 4 1.1 General ................................................................................................................................................................................. 4 1.2 Service and maintenance ..................................................................................................................................................... 4 1.3 Guarantee ............................................................................................................................................................................. 4 1.4 Liability ................................................................................................................................................................................. 4 1.5 Identification ........................................................................................................................................................................ 4 1.5.1 Identification plate ............................................................................................................................................. 4 2 INFORMATION ............................................................................................................................................................................ 4 2.1 Safety .................................................................................................................................................................................... 4 2.1.1 Warnings and symbols ....................................................................................................................................... 4 2.1.2 General .............................................................................................................................................................. 5 2.1.3 Organizational measures ................................................................................................................................... 5 2.1.4 Maintenance & repair ........................................................................................................................................ 5 2.1.5 Electrical safety .................................................................................................................................................. 5 2.1.6 Magnetism ......................................................................................................................................................... 5 2.1.7 Operation ........................................................................................................................................................... 5 2.1.8 Fire and explosion .............................................................................................................................................. 5 2.1.9 Chemicals ........................................................................................................................................................... 6 2.2 Transport, lifting and storage ............................................................................................................................................... 6 2.3 Features ................................................................................................................................................................................ 6 2.3.1 General .............................................................................................................................................................. 6 2.3.2 Construction ...................................................................................................................................................... 6 2.3.3 Engine Control Unit ............................................................................................................................................ 6 2.3.4 Documentation .................................................................................................................................................. 6 2.4 Main components ................................................................................................................................................................ 7 3 TECHNICAL INFORMATION ......................................................................................................................................................... 8 3.1 Parts and relevant functions................................................................................................................................................. 8 3.1.1 Engine ................................................................................................................................................................ 8 3.1.2 AC Permanent Magnet Alternator ..................................................................................................................... 8 3.1.3 Engine Control Unit and DDC ............................................................................................................................. 8 3.1.4 Power Module Genverter .................................................................................................................................. 9 3.1.5 Battery charger .................................................................................................................................................. 9 3.1.6 Load indicators ................................................................................................................................................... 9 3.1.7 Fuel .................................................................................................................................................................... 9 3.1.8 Lubricating oil .................................................................................................................................................... 9 3.1.9 Oil cooling heat exchanger .............................................................................................................................. 10 3.2 Technical data .................................................................................................................................................................... 11 3.2.1 General ............................................................................................................................................................ 11 3.2.2 Fuel specifications ............................................................................................................................................ 13 3.2.3 Lubricating oil specifications ............................................................................................................................ 13 3.2.4 Electrical diagrams ........................................................................................................................................... 13 4 OPERATION .............................................................................................................................................................................. 14 4.1 General ............................................................................................................................................................................... 14 4.2 Optional variable speed mode ........................................................................................................................................... 14 4.3 Operating instructions ........................................................................................................................................................ 14 4.3.1 Summarized operating instructions (daily use) ............................................................................................... 14 4.3.2 Extended operating instructions ...................................................................................................................... 15 5 MAINTENANCE ......................................................................................................................................................................... 17 5.1 Maintenance intervals ........................................................................................................................................................ 17 5.2 Alternator ........................................................................................................................................................................... 17 5.3 Engine ................................................................................................................................................................................. 17 5.3.1 Preliminary instructions ................................................................................................................................... 17 5.3.2 Bleeding fuel lines ............................................................................................................................................ 17 5.4 Regular maintenance ....................................................................................................................................... 17 5.4.1 Changing oil and cleaning the oil strainer ........................................................................................................ 17 5.4.2 Checking the battery ........................................................................................................................................ 17 5.4.3 Draining water from the fuel tank ................................................................................................................... 17 5.4.4 Cleaning the external coolant radiator ............................................................................................................ 18 CONTENTS W-GV4 Scalino outdoor — April 2017— EN 3 5.4.5 Replacing the fuel filter .................................................................................................................................... 18 5.4.6 Air filter element .............................................................................................................................................. 18 5.4.7 Checking hoses and electrical connections ...................................................................................................... 18 5.4.8 Retightening cylinder head bolts and adjusting valve clearance ..................................................................... 18 5.5 Putting out of service ......................................................................................................................................................... 19 6 TROUBLESHOOTING ................................................................................................................................................................. 20 6.1 General ............................................................................................................................................................................... 20 6.2 Alternator/ electrical faults ................................................................................................................................................ 20 6.2.1 Troubleshooting table for alternator ............................................................................................................... 20 6.3 Engine faults ....................................................................................................................................................................... 20 6.3.1 General ............................................................................................................................................................ 20 6.3.2 Troubleshooting table for engine .................................................................................................................... 20 6.5 Warnings ............................................................................................................................................................................ 23 6.6 Service address ................................................................................................................................................................... 23 7 SPARE PARTS LIST ..................................................................................................................................................................... 24 Suppliers Declaration of Conformity/Incorporation INFORMATION 4 W-GV4 Scalino outdoor — April 2017 — EN 1 INTRODUCTION 1.1 General This manual serves as a guideline for the safe and effective operation, maintenance and possible correction of minor malfunctions of the W-GV4 Scalino manufactured and marketed by WhisperPower. It is therefore obligatory that every person who works on or with the W-GV4 Scalino must be completely familiar with the contents of this manual, and that he/she carefully follows the instructions contained herein. Both safety and durability rely very much on the correct identification, installation and a good understanding of ratings, features, design, maintenance and operation procedures. The information, specifications, illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press. Our policy is one of continued development and we reserve the right to amend any technical information without prior notice. Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer, distributor, or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof. 1.2 Service and maintenance Regular service and maintenance should be carried out according to the directions in this manual. For service and maintenance one can appeal to the manufacturer or the dealers. 1.3 Guarantee WhisperPower guarantees that this Genverter has been built according to good workmanship, according to the specifications in this manual and according to European Community safety regulations. During production and prior to delivery, all of our Genverters are tested and inspected. This Genverter’s proper operation is subject to guarantee. The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries for the North of the Netherlands number 01120025 and are available on request. The guarantee period is two years, limited to 1000 running hours. Some aspects of our guarantee scheme are given here in more detail: Guarantee does not cover failures that are caused by misuse, neglect or a faulty installation. WhisperPower cannot be held responsible for damage caused by the unattended running Genverter. 1.4 Liability WhisperPower does not accept responsibility for damage, injuries or casualties which are the result of operation of the Genverter in specific conditions which brings dangers which could not be foreseen, or could be avoided by additional measures. WhisperPower does not accept liability for damage due to use of the Genverter, possible errors in the manuals and the results thereof. 1.5 Identification 1.5.1 Identification plate All required identification data are on the identification plate, providing the following information. The identity of the Genverter is given by the SERIAL NUMBER. POWER The identification plate gives the maximum load in kVA (= kW) calculated with power factor one. When calculating a load one should always take into account the power factor or cos phi of this load. The load should never exceed the nominal power as shown on the identification plate. Power is rated at an ambient temperature of 25ºC. For higher temperatures the Genverter has to be de-rated. The identification plate also shows the maximum CURRENT that is acceptable at the specified frequency, voltage and power factor. DC VOLTAGE is the voltage of the starter battery. The (approximate) net dry WEIGHT is shown in kg. This is without fuel, oil, cooling liquid, packing and external installation equipment The CE symbol shows that the Genverter has been built according to European Community safety regulations. Refer to EC Declaration of Conformity for more details. 2 INFORMATION 2.1 Safety 2.1.1 Warnings and symbols Safety instructions and warnings are marked in this manual by the following pictograms, indicating that a piece of equipment, routine, circumstance, procedure, etc. deserves extra attention: WARNING This warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment, severe personal injury or loss of life.