USERS MANUAL M-SC3.5 - 3000 RPM - Marine diesel generating set 230V / 50Hz MasterBus controlled Art.nr. 40261131 WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel.: +31-512-571550 Fax.: +31-512-571599 www.whisperpower.eu V1.
TABLE OF CONTENTS TABLE OF CONTENTS: 1 INTRODUCTION .............................................................................................................................................................. 4 1.1 General .............................................................................................................................................................. 4 1.2 Service and maintenance ................................................................................................
TABLE OF CONTENTS 4.3 4.2.2 Bleeding fuel lines ........................................................................................................................... 21 4.2.3 Valve clearance ............................................................................................................................... 21 4.2.4 Replacing fuel filter .......................................................................................................................... 21 4.2.
INTRODUCTION 1 INTRODUCTION 1.1 GENERAL 1.2 The M-SC3.5 Marine Diesel Generating set is manufactured and marketed by Whisper Power. It is important to read this manual before installing and operating the generating set. Both safety and durability rely very much on the correct identification, installation and a good understanding of ratings, features, design, maintenance and operation procedures.
INTRODUCTION Example 4: Neglect Whisper generators have an option for an auto start/stop mode or interval mode. Whisper Power cannot be held responsible for damage caused by the unattended running generator. Guarantee means that faulty parts are repaired or replaced free of charge. If necessary the whole generator unit will be exchanged.
INTRODUCTION 1 2 The identity of the generating set is given by the SERIAL NUMBER. When this number is available the manufacturer can trace the specifications of the generating set. On the identification plate are also some basic features of the set. POWER The identification plate gives the nominal maximum continues 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 power should never exceed 3 kW.
INFORMATION 2 INFORMATION 2.1 SAFETY 2.1.1 General When correctly installed and used in normal circumstances this generating set fulfils EC safety regulations. This generating set could be part of an installation or could be used in a way that additional regulations of the EC or other authorities have to be taken into account. Circumstances could make it also necessary to take additional measures. Be aware of wet conditions and hazardous environments caused by explosive gases etc. 2.1.
INFORMATION • When service has to be carried out while the engine is running, be aware of moving parts like V-belts. • • • • • • 2.1.6 The generating set should be operated by authorised personnel only. Be aware of hot parts and especially parts of the exhaust system and the cooling system. If the generating set is unsafe, fit danger notices and disconnect the battery positive (+) lead so that it cannot be started until the condition is corrected.
INFORMATION more. Refer to the separate operating manual of the MasterView Easy for details. 2.3.2 Remote control panel The generating set as well as the rest of the electrical system can be monitored and controlled by any MasterBus compatible remote control panel. The MasterView Easy is a MasterBus compatible monitoring and control panel that comes as standard with the generating set. A MasterBus communication cable (15 mtr) as well as two terminating devices is included in the delivery. 2.3.
INFORMATION 2.4 COMPONENTS 2.4.
INFORMATION 2.4.2 Local control panel 2.5 2.5.1 TECHNICAL INFORMATION AC alternator The single phase alternator is directly coupled, one bearing, brushless, rotating field design, two poles (3000 RPM) and self regulating. Residual magnetism causes a small voltage over the stator windings and allows a current to flow in the windings, which is magnified because of the feed back effect between rotor and stator. The field windings in the rotor are short-circuited over a diode to rectify the current.
INFORMATION It is very important to use the correct oil specification. Very often local oil suppliers recommend a higher class, because they assume that a higher class is allowed. This is not the case. One should not follow these recommendations. Using the wrong specification will cause high oil consumption. is standard included in the delivery of the generating set. Refer to the separate operating manual of the MasterView Easy for operation instructions. 2.5.
INFORMATION 2.5.8 Technical data GENERAL Model RPM Alternator Engine Number of cylinders Displacement Bore X stroke Combustion air consumption Continuous power engine Cooling system Cooling water consumption Cooling water pump Fuel lift pump engine Starting system electrical Starting battery (optional) Fuel consumption Control M-SC3.5 3000 water cooled, synchronous Kubota diesel, model OC60 (Japan) 1 276 cm3 72x68 mm 0.38 m3/min. at nominal RPM 3 kW nett Indirect cooling by raw water 10-12 l/min.
INFORMATION 2.5.9 DC wiring diagrams Fig. 5: DC wiring M-SC3.5 grounded (part. Nr. 41200500) 14 May 2010 / M-SC3.
INFORMATION Fig. 6: DC wiring M-SC3.5 ungrounded (part. Nr. 41200506) EN / M-SC3.
INFORMATION 2.5.
INFORMATION 2.5.
OPERATION 3 OPERATION 4 3.1 GENERAL The generating set is operational after full installation and filling up with: fuel, engine lubricating oil and cooling liquid, filling the starter battery with acid, connecting the battery to earth and connecting the MasterView Easy remote panel. 5 Power source selector switch (off/shore power/generator power). Switch to power source Generator.
OPERATION 6 7 If no Masterswitch is used: Switch main Power Source Selector switch to "OFF" or switch off all devices. Switch on the battery switch. Starting the generator: By pushing the Start / Stop button on the Local control panel or by giving a start command from the MasterView Easy, the electric system is activated, the fuel lift pump starts pumping and the starting procedure will begin.
OPERATION disconnect the battery with the engine stopped and all switches in "OFF" position. the engine can trip the "high temperature" alarms. In that case, a restart of the engine is not possible for some time. It is also recommended to switch off electrical users prior to stopping the generator because of the voltage drop that occurs as the engine comes to a halt. Such voltage drops may cause damage to electric motors, compressors (in refrigerators or air conditioners etc.).
MAINTENANCE 4 MAINTENANCE 4.1 ALTERNATOR The alternator does not require any maintenance. Periodic inspection and cleaning is recommended, depending on environmental conditions. However when the alternator has been idle for a long period attention to winding condition is recommended. The condition of windings can be assessed by measurement of insulation resistance to earth. The CAPACITOR should be disconnected during this test. A 500V ‘megger’ or similar instrument should be used.
MAINTENANCE 4.2.5 Cleaning oil strainer The oil strainer is behind a plug on the bottom of the engine. In the strainer is a magnet to catch the metal parts which are in the lubricating oil. Once per 1000 hours or when the oil is contaminated one can clean the strainer by washing it with petrol or a solvent. A green rubber plug in the capsule gives access to the strainer. Before taking out the plug one should sump the oil. Use tissues to avoid spilling oil in the capsule. 4.
MAINTENANCE is cooled by seawater which is pumped by the PTO driven impeller pump through the cooler elements in the generator housing. All parts of the cooling system are of corrosion free and seawater resistant materials such as brass and gunmetal. In case of gathering of dirt in the system it could be cleaned by compressed air. When overhauling the engine one could clean the parts thoroughly or replace. When the generator set runs less than 100 hours a year the oil should be changed yearly. 4.3.
TROUBLE SHOOTING 5 TROUBLE SHOOTING 5.1 ALTERNATOR/ ELECTRICAL FAULTS Beware of parts which are live! Before working on the generator, remove the 30Amp fuse from the local control panel (see figure 3) to prevent the engine from starting. 5.1.1 General If any problem should occurs, check basic conditions and examine all external wiring, switch gear and circuit breakers. Also check if measuring instruments give the correct value. If in doubt, measure directly on the 5.1.
TROUBLE SHOOTING DC warnings and failures Meaning What to do? No failure UDC Bat low None (no failure detected) Battery voltage of the starter battery is too low (flat battery) Charger failure Defective charger, charger fuse blown Charger temp Internal temperature of battery charger circuit on local control panel too high DC current through the fuel lift pump was too high DC current through the pull to stop relay was too high DC current through the glow plug was too high DC current through the star
TROUBLE SHOOTING 5.1.3 Other electrical problems PROBLEM POSSIBLE CAUSE WHAT TO DO? No output (Voltage) at all. • Circuit breaker "off" or faulty fuse. Check switches and fuses and measure directly on the alternator to exclude external causes. Check the engine RPM and adjust (refer to special procedures). Check the residual magnetism and flash the alternator (refer to special procedures). Check by independent excitation if the problem is in the capacitor or in the windings.
TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE WHAT TO DO? Generator is not able to start an electric motor. If the generator is unable to supply enough power to start an electric motor (230V), this is usually because this motor draws too much current during starting. Check the electric motor’s current draw required for starting. This should not exceed 70% of the rated generator output current. This could be remedied by providing stronger capacitors to the motor or using a "soft-start".
TROUBLE SHOOTING 5.2 ENGINE FAULTS When the engine does not start instantly, prolonged cranking can fill up the exhaust system with cooling water because of the water injected exhaust. When the water enters the cylinder through the valves this will bring severe damage to the engine. When the engine does not start and repeated cranking is necessary shut off the seawater inlet. Open the valve immediately after the engine has started.
TROUBLE SHOOTING 5.2.3 Other engine related problems PROBLEM POSSIBLE CAUSE WHAT TO DO? Diesel engine fails to crank, the starter makes clicking noises, or the engine cranks very slowly • Almost certainly this is an electrical problem. The remote control panel will indicate a failure code related to the DC voltage (see 5.1.2) • One other possibility is that the engine is locked by water in the cylinder or there is other severe damage.
TROUBLE SHOOTING PROBLEM Engine runs irregularly POSSIBLE CAUSE WHAT TO DO? • Loss of compression by wear out or damage. Repair by Whisper Power. • Unsuitable contaminated fuel. • Lack of fuel. Fill up with fuel or replace by better quality. • Choked fuel filter. Check fuel filter and fuel lift pump: clean or replace if necessary. Check if electrical load is fluctuating • Disturbances on the electrical system/ user side. • Faulty fuel lift pump. • Choked air filter. • Lack of air.
TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE WHAT TO DO? Engine starts, but stops after 10 up to 30 seconds Protection system stops the engine; this can be caused by oil pressure failure, lack of cooling water (exhaust temperature alarm). Overload, loose wire or faulty alarm switch. Display on MasterView Easy Panel will help to indicate failure. See section 5.2.2. Engine stops by itself • Overload or short circuit. Switch off the consumers and test for short circuit.
TROUBLE SHOOTING PROBLEM Engine stops very slowly 5.2.4 POSSIBLE CAUSE WHAT TO DO? • • • • • • Fill up with oil. Low oil level. Water inlet system blocked. Broken impeller. Water strainer choked. Heat exchanger choked. Faulty thermostat Check the cooling system thoroughly. Check the thermostat or replace. • Engine should stop within 20 seconds. Warnings Generator must be shut off immediately if: 5.2.
TROUBLE SHOOTING 5.3 SPECIAL PROCEDURES ALTERNATOR 5.3.1 Residual voltage check / excitation procedure When residual magnetism disappears there is no residual voltage. Residual magnetism can disappear after the generating set being out of service for a long period or suffered a short circuit. This can be solved by charging the capacitor ("flashing") independently with a small 9 Volt battery. This can be done while the engine is stationary and the wiring is connected.
TROUBLE SHOOTING 5.4 5.4.1 SPECIAL PROCEDURES ENGINE Setting the RPM RPM is set by the manufacturer and should not need readjustment! However a very slight offset after running in could occur. RPM can be measured by a frequency meter. Before readjustment check any other explanation for the wrong speed. Engine speed is set at the factory at nominal 3000 (50 Hz) RPM. A RPM drop of 5% at full load is acceptable. Therefore a no load setting should be at ± 3150 RPM = 52.5 Hz.
TROUBLE SHOOTING 5.4.4 1 2 3 4 How-ever one can take off the complete alternator housing. Disassembling instructions It could be necessary for repair or checks to disassemble the generating set. One can take off the white cover easily for regular maintenance and inspection. For further repair or inspection one can take off the upper green part as well.
SPARE PARTS LIST 6 SPARE PARTS LIST A parts manual in English is available as an option; number: 40200180(***). A work shop manual in English is available as an option; number: 40200170(***).
SPARE PARTS LIST Figure 18: Waterpump type K EN / M-SC3.
MAINTENANCE LOG MAINTENANCE LOG First service after 50 hours: Hour counter: Remarks: Next service (every 150 hours): Hour counter: Remarks: 38 May 2010 / M-SC3.
Kelvinlaan 82, 9207 JB Drachten, The Nederlands Tel : + 31-512-571550 / Fax : + 31-512-571599 www.whisperpower.eu / info@whisperpower.
