R Personal Power Station User’s Manual PPS16 Marine and Land Version Kerosene or Diesel Fuel 12 or 24 Volt Battery Bank Capacity 2 Personal Power Station R R STANDBY STARTING RUNNING STOPPING START FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE STOP ON FUEL OFF WHISPER TECH LIMITED
Whisper Tech Ltd. reserves the right to revise or change the specifications of its products. 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, R Personal Power Station, and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited.
Read this manual from cover to cover before attempting to use the WhisperGen. This manual contains important operating, care and maintenance, trouble shooting, warnings and safety procedures. Follow them! If you don’t understand a point in this manual, don’t guess. Get help! Contact your authorised WhisperGen representative. Along with the warnings, instructions and procedures in this manual, the user should also observe such other common sense procedures generally applicable to equipment of this type.
Table of Contents INTRODUCTION The WhisperGen ......................................................................................................................... 1,2 Introduction............................................................................................................................... 1 What it does ............................................................................................................................. 1 How it works ............................................
MAINTENANCE Introduction .................................................................................................................................. 45 Maintenance Schedule............................................................................................................ 45,46 Removing the Enclosure Lid ........................................................................................................ 47 General Checking ..................................................................
The WhisperGen Introduction Congratulations on purchasing a WhisperGen PPS16. This manual is designed to allow you to quickly learn how to safely operate your WhisperGen. Please keep this manual for future reference and read it before operating or maintaining your WhisperGen. In this manual, warnings against hazards are marked with the symbol shown on the left. Heed all warnings at all times.
How It Works The WhisperGen PPS16 is based on a four-cylinder Stirling-cycle (external combustion) engine that repeatedly heats and cools a mass of pressurised nitrogen gas. Each time the gas is heated and cooled, the changing gas pressure causes the pistons to move up and down. This mechanical motion, via a special mechanism called the “wobble yoke”, rotates an alternator to generate DC electricity which can be used to charge a lead-acid battery bank.
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No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 5 Description WhisperGen PPS16. Engine Block. Exhaust heat exchanger. Coolant header tank. Coolant pump. Hot water cylinder (optional). Space heater (optional). Marine heat exchanger. Seawater pump. Electronics enclosure. Current shunt. DC appliances (12/24 Volt). Inverter (DC to 230/110 Volt AC). Electrical appliances (230/110 Volt AC). Battery bank (12/24 Volt). Circuit breaker. Fuel tank. Fuel filter. Fuel pump.
Technical Specifications Specifications subject to change without notice Feature Specification Remark Prime mover 4-cylinder Stirling-cycle engine pressurised to 28 bar with nitrogen. Power output Co-generation of heat and electricity. Heat 5kW useable heat. Closed thermodynamic cycle. Heat output depends on operating conditions. Electrical 750W electrical. Gross output depends on operating conditions. Duty cycle 1 to 24 hours per day.
Feature Specification Remark Cooling system Cooling method Primary Cooling: Automotive type glycol-based corrosion-inhibited antifreeze. Removes heat from engine. Secondary Cooling: Water-cooling (marine applications). External Radiator (land applications). Heat exchangers Internal exhaust and marine heat exchangers. Exhaust temperature 80°C nominal, 95°C maximum. Heat is transferred to hot water cylinder(s) and space heater(s). Requires external coolant pump and seawater pump.
Summary of Parts 9 11 10 12 13 8 7 2 6 1 5 2 Personal Power Station R R STANDBY STARTING FAULT AUTOCHARGE RUNNING EXT CONTROL STOPPING HEAT MANAGE START ON STOP FUEL OFF WTL0005 4 3 R 8
No 1 2 3 4 5 6 7 8 9 10 11 12 13 9 Name Function Enclosure The fibreglass-reinforced cover that protects the internal parts of the WhisperGen. Electronics Enclosure The electronics, including a microcomputer, that controls all WhisperGen functions and regulates power supply to and from the WhisperGen and battery bank. Fuel Valve A manually operated valve that isolates the WhisperGen from its fuel supply, stopping combustion and shutting down the engine.
Control Panel Parts 5 R STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START 4 STOP 3 WTL0006 1 2 No Name Function 1 START Key 2 SELECT Keys 3 STOP Key The key that shuts down the WhisperGen. 4 Indicators The lights that indicate the status of the WhisperGen system. STANDBY: the WhisperGen is ready to start. STARTING: the WhisperGen is starting. RUNNING: the WhisperGen is operating. STOPPING: the WhisperGen is stopping. FAULT: a fault or warning is present.
Safety Precautions Please read and understand this section ENTIRELY before operating or maintaining the WhisperGen. Not heeding the warnings or recommendations could damage the WhisperGen, cause personal injury, and/or void the warranty. WTL0000 User's Manual In some countries, this manual must be permanently placed alongside the WhisperGen and maintained in a readable condition. Consult your local authority for information.
Never remove the burner earthing strap as this will cause the fuel line to act as the earthing path for the glow plug. The fuel could heat up, causing a malfunction or a fire. WTL0024 Do not use fuels other than the specified class of fuel as this may damage the WhisperGen and/or cause a fire. WTL0054 Air bubbles present in the fuel line can cause the WhisperGen to malfunction – bleed the fuel line after filling a completely empty fuel tank.
Do not operate the WhisperGen in a potentially explosive environment. H2 O2 Personal Power Station R ON FUEL OFF WTL0063 Do not store rags or other items inside or beside the WhisperGen as the air circulation through the WhisperGen may be disrupted. Personal Power Station R ON FUEL OFF WTL0064 Do not drill holes in the enclosure. Air circulation through the WhisperGen may be disrupted.
During normal operation of the WhisperGen, the enclosure lid and electronics enclosure lid must be fitted. 2 Personal Power Station ON R FUEL OFF WTL0010 Bake Time____ 1 2 4 5 7 8 3 6 9 0 OPEN START Do not sit anything on the WhisperGen or press down hard on the top. Personal Power Station R ON FUEL OFF WTL0059 Do not expose the WhisperGen to large physical impacts. Personal Power Station R ON FUEL OFF WTL0060 Do not expose the WhisperGen to excessive vibration.
1. Check x Ensure that maintenance procedures and schedules as recommended in this manual are adhered to at all times. 2. Check y 3. Clean p 4. Clean q WTL0069 Perform maintenance procedures mentioned in this manual only. If in doubt, call your authorised WhisperGen service agent. WTL0068 Before the WhisperGen is transported by air or disposed, fluids in it must be drained and the engine must be depressurised. Consult your authorised WhisperGen service agent for advice.
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 • Display and edit system parameters of the WhisperGen. You should read and understand all safety precautions before operating your WhisperGen.
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 Menu Heat Manage Fault / Warning Menu Warning Code Edit to clear Extra Info Menu Alt Current Air % Temp Setpoint Current Warning Coolant Temp Auto-charge Last Warning Bus Voltage Ext.
Starting the WhisperGen To manually start the WhisperGen: 1. Check that the STANDBY indicator on the control panel is lit. If the fault indicator is constantly lit, you will need to clear the fault – 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.
3. Hold down START on the control panel until all indicators flash and a beep is heard. The STARTING indicator will light up and “Manual start” will be displayed on the control panel. As an anti-tamper feature, short presses of the START key are ignored.
Stopping the WhisperGen Manual Stopping The default setting of the Heat Manage option is OFF. Unless it is turned ON, the WhisperGen automatically stops once the battery bank is fully charged - you do not need to manually stop the unit. Should you wish to manually stop the WhisperGen refer to the following: 1. Hold down STOP on the control on the control panel until a beep is heard. The STOPPING indicator will light up and “Running down” will be displayed on the control panel.
Emergency Stopping To stop the WhisperGen in an emergency: 1. Turn off the fuel valve in front of the WhisperGen. ON FUEL OFF Personal Power Station R ON FUEL WTL0012 OFF 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.
Setting the Maximum Run Time If the WhisperGen is started manually or from a remote switch, you can limit the operating duration of the WhisperGen by setting a maximum operating time. To set the maximum operating time of the WhisperGen: 1. Access the default display on the control panel by pressing Displaying System Information - Displaying Information. < repeatedly.
3. Press > to display the first item on the User Menu R Heat Manage STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 4. Press ∨ to scroll down to Max Run Hours. R Max Run Hours STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 5. Press > to begin editing the maximum operating time of the WhisperGen.
6. Press ∧ or ∨ to select the maximum number of operating hours for the WhisperGen. If 25 (hours) is selected, the WhisperGen will run continuously until the battery bank is fully charged. R Max Run Hours STANDBY STARTING RUNNING STOPPING 21 FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 7. Optional: press < repeatedly to return to the default display. You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel.
Remote Controlling You can start and/or stop the WhisperGen using a remote on/off switch, timer, or thermostat, if one of these is fitted. To set the remote switch to start/stop the WhisperGen: 1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in the section entitled Setting the maximum Run Time. 2. Press ∨ to scroll down to Ext. Control. R Ext. Control STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 3.
5. 6. 7. 8. Press < to quit editing Ext. Control. Press ∨ to scroll down to Ext Cont Mode. Press > to begin editing the external control mode setting. Press ∧ or ∨ to select an option: 1, 2 or 3. These options are described in the table below. Setting Control Options Control Logic 1 Starting only The WhisperGen will start when the remote switch is closed and will continue running even if the remote switch is then opened.
Managing the Battery Bank Stages of Charging Current Supplied to Battery Bank Every time the WhisperGen is operated, it charges the battery bank. There are three stages in a typical charging cycle as shown below: Voltage across Battery Bank Terminals Time Bulk-charging Absorption-charging Float-charging Time Bulk-charging Absorption-charging Float-charging The battery bank is charged at the maximum rate. The voltage typically rises 2 or 3 Volts while the current is maintained at a fixed level.
Auto-Charging the Battery Bank You can set the WhisperGen to automatically start and charge the battery bank when the battery bank charge level is low. To set the WhisperGen to auto-charge the battery bank: 1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in section entitled Setting the Maximum Run Time. 2. Press ∨ to scroll down to Auto-charge. R Auto-charge STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 3.
With the Auto-charge option turned ON, the WhisperGen will automatically start whenever the battery bank charge level falls below a preset level. This “threshold” level is set during the installation of the WhisperGen according to the needs of your particular application. If you wish to change it, contact your authorised WhisperGen agent. The battery bank is typically charged in three stages as described in section entitled Stages of Charging.
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. You may however set the coolant temperature to any temperature from 45°C to 70°C. To set the temperature of the coolant: 1.
Turning On Heat Management Whenever it is running, the WhisperGen maintains the coolant temperature at approximately the set point until the battery bank is fully charged. When the battery bank is fully charged, the WhisperGen stops and returns to the standby mode and the coolant temperature is no longer maintained. You can however turn on the heat management option to keep the WhisperGen running to maintain the coolant temperature continuously even after the battery bank has been fully charged.
Clearing Faults and Warnings There are two types of errors that the WhisperGen automatically detects, as described below: Error Type Warning Meaning Indication Error that is minor or which • indicates that a fault might be developing. • • Fault Functional error that causes the WhisperGen to shut down. • • • The FAULT indicator on the control panel flashes while the error exists. No error message is displayed on the control panel. The WhisperGen continues operating.
When the WhisperGen is started, any warning present is automatically cleared. To manually clear a warning: 3. Access the main menu on the control panel – follow steps 1 and 2 of the procedure outlined in section entitled Setting the Maximum Run Time. 4. Press ∨ to scroll down to Fault/Warning Menu. R Fault/Warning Menu STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 5. Press > to display the first item on the Fault/Warning Menu.
6. Press > to begin clearing the warning. R Warning Code Edit to clear STANDBY STARTING RUNNING STOPPING [102] FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 7. Press ∨ to clear the warning. The Fault indicator turns off. R Warning Code STANDBY STARTING RUNNING STOPPING [0] FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 8. Optional: press < repeatedly to return to the default display.
Adjusting the LCD Adjusting the Contrast The control panel has a liquid-crystal display (LCD) which shows system information. The contrast of the LCD can be manually adjusted. To increase the contrast of the LCD: Hold down < and ∧ repeatedly until the desired contrast is achieved. R STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 To decrease the contrast of the LCD: Hold down < and ∨ press repeatedly until the desired contrast is achieved.
Adjusting the Backlight The LCD has a backlight which allows the LCD to be more clearly seen in dark environments. The backlighting can be manually adjusted. To adjust the LCD backlight: 1. Hold down < and > press repeatedly until the desired level of backlighting is achieved. Three levels of backlighting are available namely: high, low, and off.
Displaying System Information Available Information The control panel displays information regarding the status of the WhisperGen system. The following information, structured as shown in section entitled Quick Reference - Information Structure, may be obtained from the control panel: Default Display Parameter Meaning Typical Range Battery Volts The voltage across the terminals of the battery bank. 12V battery bank: 9.5 to 15.5 Volts. 24V battery bank: 19.0 to 31.0 Volts.
User Menu Parameter Meaning Typical Range Heat Manage The heat management function – see section ON or OFF (default). entitled Turning on heat mangement. Temp Setpoint The temperature in °C that the coolant is to be maintained at during operation of the WhisperGen – see section entitled Setting the coolant temperature. 45 to 70°C (default is 60°C). Auto-charge The Auto-charge function – see section entitled Auto-charging the battery bank. ON or OFF (default). Ext.
Extra Info Menu Parameter Meaning Typical Range Alt Current The electric current in Amperes that is 12V: -20 to 75A. being generated by the WhisperGen 24V: -10 to 37A. alternator. Positive values indicate current generation and negative values current flow to the WhisperGen from the battery bank during cranking. Air % The power applied to the air blower as a 0 to 100%. percentage of the maximum power that can be applied to it. The higher the air flow rate, the higher the combustion rate.
Extra Info Menu Parameter Meaning Typical Range Isolate Relay The position of the main electrical isolator relay located inside the WhisperGen. It should be ON when the WhisperGen is operating. ON or OFF. Power Relay The power supply to ancillary components ON or OFF. such as the fuel pump, coolant pump, etc. The power supply should be ON when the WhisperGen is operating. O2 Value The quantity of oxygen in the exhaust. This 200 to 2500. reflects the air/fuel ratio.
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: 1. Press < repeatedly until one of the default display parameters appear.
To display a menu at a higher level: 3. Press <. For example, if Alt Current is displayed initially, then to display the main menu, press <. To scroll up within a menu: 4. Press ∧ . For example, if Bus Voltage is displayed initially, then to display Alt Current, press ∧ twice. R Alt Current STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 To scroll down within a menu: 5. Press ∨.
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. All other parameter settings can be displayed but not edited. To edit the setting of a parameter: 1.
3. Press ∧ or ∨ to edit the setting. In the above example, if the existing setting is OFF and you wish to turn on auto-charging, then press ∧ to change the setting to ON. R Auto-charge STANDBY STARTING RUNNING STOPPING On FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 4. Optional: press < repeatedly to return to the default display. You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel.
Maintenance Introduction This section outlines maintenance procedures for your WhisperGen. It will show you how to: • Develop a basic maintenance routine for the WhisperGen; • Maintain the fuel and coolant systems; • Check the battery bank connections; and • Replace the glow plug, fuses, FID, oxygen sensor, and evaporator. You should read and understand all safety precautions before operating or maintaining your WhisperGen.
The following procedures may need to be carried out if faults develop: Procedure Bleeding the fuel line. How When See section - Bleeding the fuel line. • • • When there is air trapped in the fuel line. After a fuel run-out occurs. After the fuel filter is cleaned. Cleaning the fuel pump filter. See section - Cleaning the fuel • pump filter. • Bleeding the coolant circuit. See section - Bleeding the coolant circuit. When there is a coolant flow fault. Replacing the glow plug.
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. To remove the enclosure lid: 1. Remove the rubber rings from the upper plastic hooks on both sides of the WhisperGen. WTL0018 2. Carefully lift the enclosure lid.
General Checking The following general checking routine helps to ensure the proper functioning of the WhisperGen and should be performed every six months. 1. Start the WhisperGen. 2. Check that the WhisperGen exhaust does not contain high levels of smoke. When the WhisperGen first starts, smoke may be released initially. However, only steam should be visible several minutes after the WhisperGen has started. 3. Check all exhaust piping in occupied areas for leakage.
Checking the Fuel The fuel level should be checked regularly to ensure a constant fuel supply to the WhisperGen. How often the fuel needs to be checked and replenished depends on the operating conditions of the WhisperGen and the size of the fuel tank. In general, the WhisperGen consumes 0.5 to 0.85 litres of fuel per hour of operation. This applies to machines using either diesel or kerosene fuel. To check the fuel level: 1. Remove the fuel tank cap.
Bleeding the Fuel Line Filling a fuel tank that has run empty may introduce into the fuel line air bubbles 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. The coolant and seawater pumps may start when the fuel line is bled. (marine version only) To bleed the fuel line: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
4. Uncrew the fuel line fitting on top of the burner. 2 WTL0022 5. Connect a clear plastic hose to the exposed end of the fuel line, and allow the hose to drain into a container that will hold at least a litre of fuel. Fuel Line Plastic Hose Fuel Container WTL0023 6. Access the Main Menu on the control panel - follow the first two steps of the procedure outlined in the section entitled Stopping the WhisperGen - Setting the maximum run time. 7. Press ∨ to scroll down to Installation Menu.
8. Press > to display the third item on the Installation Menu, Fuel Bleed. R Fuel Bleed STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 9. Press > to begin editing the fuel bleeding setting. 10. Press ∧ to select ON. Fuel will be bled through in pulses for 60 minutes. You can stop the fuel pump at any time by pressing ∨. At least twice the volume of fuel in the entire fuel line connecting the fuel tank to the evaporator must be bled.
Cleaning the Fuel Pump Filter Fuel supplied to the WhisperGen must have low levels of contamination. The fuel filter inside the fuel pump should be cleaned if faults related to fuel supply occur frequently or if the power output is constantly low. To clean the fuel filter: 1. Turn off the fuel tank valve and the WhisperGen fuel valve. Fuel Pump Fuel Tank Fuel Tank Valve Auxiliary In-line Filter WTL0025 FUEL 2. Place a container below the fuel pump to collect fuel spillage. 3.
5. Remove the filter from the fuel pump. WTL0028 6. Clean the filter by either blowing clean compressed air through it or by brushing it in clean diesel or kerosene. Do not use a cloth rag to clean or dry the filter. Fuel Filter WTL0029 7. Replace the filter in the brass fitting and secure the brass fitting to the fuel pump, making sure that the o-ring is correctly seated. 8. Secure the fuel line to the fuel pump. 9. Turn on the fuel tank and WhisperGen fuel valves. 10. Bleed the fuel line. 11.
Checking the Coolant The coolant level should be checked regularly to ensure a constant circulation of coolant through the WhisperGen. How often the coolant needs to be checked and replenished depends on the size of the coolant header tank and the coolant circuit. In general, you should check the coolant level at least once a month. The cooling system of the WhisperGen is vital to its performance. If the coolant level is not maintained correctly, damage may occur. To check the coolant level: 1.
Bleeding the Coolant Circuit Filling a coolant header tank in which the coolant level has fallen below the outlet level of the tank, may introduce into the coolant circuit air bubbles that could cause the WhisperGen to malfunction. Should this occur bleed the coolant circuit. To bleed the coolant circuit: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. To prevent unintentional starts of the WhisperGen, heed the warning given at the beginning of this section. 2.
5. Press > to display the first item on the Installation Menu. R Hx Nozzle Bleed STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 6. Press ∨ to scroll down to Coolant Bleed 1. R Coolant Bleed 1 STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 7. Press > to begin editing the coolant bleed setting. 8. Press ∧ to select ON. the coolant pump will be turned on to bleed the coolant circuit.
9. Get a clean rag ready. 10. Open the coolant-bleeding valve with a 6mm hex socket (or with a suitable key). Use the rag to absorb the coolant bleeding out. Oxygen Sensor Exhaust Heat Exchanger Coolant-Bleeding Valve 11. After the coolant pump has been running for five minutes, press WTL0031 ∨ to turn it off. R Coolant Bleed 1 STANDBY STARTING RUNNING STOPPING OFF FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 12. Allow the coolant to rest for one minute. 13.
15. Repeat steps 3 to 7 to begin editing the coolant pump setting, and then press ∨ to turn off the coolant pump. R Coolant Bleed 1 STANDBY STARTING RUNNING STOPPING OFF FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 16. Optional: press < repeatedly to return to the default display. You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel. 17. Replace the enclosure lid. The WhisperGen may now be started as required.
Checking Battery Bank Connections Power flows between the WhisperGen and battery bank via two power 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. If an electrical fault or warning occurs, these electrical connections may need to be checked – refer to the trouble shooting section. In general, the battery bank connections should be checked every three months.
6. Check that the electrical connections on the side of the electronics enclosure, as shown below, are intact. Before re-securing a wire/cable, first stop the WhisperGen and disconnect the WhisperGen from the battery bank by opening the circuit breaker. If stopping the WhisperGen to re-secure a wire/cable, heed the warning given at the beginning of this section to prevent unintentional starts of the WhisperGen.
Replacing the Glow Plug Should a “Glowplug cct fault” error message be displayed on the control panel, and the glow plug circuit fuse is intact, it may be necessary to replace the glow plug. In general, you should check the glow plug circuit fuse before deciding to replace the glow plug. To replace the glow plug: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. To prevent unintentional starts of the WhisperGen, heed the warning given at the beginning of this section.
5. Remove the glow plug. The glow plug may be hot. Glow Plug WTL0035 6. Insert a new glow plug with a washer into the evaporator and fasten the glow plug securely with a torque of 20 to 25Nm. Do not touch the wire coil on the new glow plug, as this will shorten its life span. 7. Replace the wire terminal and washer on the threaded tip of the glow plug and fasten the nut securely. 8. Replace the enclosure lid. The old glow plug can be returned to your authorised WhisperGen service agent for checking.
Replacing Fuses Replacing the Battery Bank Voltage Fuse The WhisperGen detects the voltage of the battery bank via two wires connected to the terminals of the battery bank as shown below. If the battery bank voltage displayed on the control panel is abnormal, it may be that the fuse in the circuit has blown. Before replacing a fuse, find out the cause of the fault. Otherwise, damage to equipment may occur.
Replacing Other Fuses The WhisperGen has fuses that protect against overloading of its electrical circuits. If a circuit is overloaded, the fuse will blow and the WhisperGen will shut down with the fault indicated on the control panel. Before replacing a fuse, find out the cause of the fault. Otherwise, damage to equipment may occur. If you are unsure of the cause of the fault, contact your authorised WhisperGen service agent for assistance. To replace a fuse (other than the battery bank voltage fuse): 1.
4. Remove the appropriate fuse and check if it has blown. The fuses are located at the bottom of the electronics enclosure and are marked with their current ratings in Ampere. Error codes displayed on the control panel help identify which circuit and therefore which fuse may possibly have blown.
Replacing the FID The condition and vertical position of the flame ionisation detector (FID) should be checked if error codes 58, 59, 60, 61, or 62 occur repetitively. To check and/or replace the FID: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. To prevent unintentional starts of the WhisperGen, heed the warning given at the beginning of this section. 2. Remove the enclosure lid and wait for the engine to cool. Do not touch the surfaces that are labelled as hot.
the electrode tip. If the FID is cracked, has less than one millimetre of the electrode protruding, or has electrical discontinuity, it should be replaced with a new one. Otherwise, the FID is re-usable. Replace if cracked Replace if there is electrical discontinuity (open circuit) Replace if less than 1mm WTL0040 7. Insert a straight length of rigid wire vertically into the FID hole. The wire should go down 135 ± 10mm. Wire Evaporator WTL0041 8.
9. Lift the wire up by 6mm (no less than 5mm and no more than 8mm) and put a second mark on the wire at the top level of the evaporator. 6 mm First mark Wire Second mark Evaporator WTL0043 10. Remove the wire from the evaporator and move the FID clip so that the distance from the clip to the electrode tip is the same as the distance from the second mark on the wire to the bottom tip of the wire. To move the clip, wedge it open slightly with a screwdriver.
Replacing the Oxygen Sensor The oxygen sensor should be replaced if error codes 10, 14, 56, 60, 61, 62, or 76 occur repetitively. In general, you should check the FID before deciding to replace the oxygen sensor. To replace the oxygen sensor: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. To prevent unintentional starts of the WhisperGen, heed the warning given at the beginning of this section. 2. Remove the enclosure lid and wait for the engine to cool.
5. Remove the oxygen sensor. WTL0047 6. Insert a new oxygen sensor into the oxygen sensor hole. Note: the ferrules should already be set in position on the oxygen sensor. The ferrules should be distanced 60mm from the sensing tip of the oxygen sensor. Do not touch the sensing tip of the oxygen sensor, as this will shorten its life span. Do Not Touch Here WTL0048 7. Finger tighten the nut that holds the oxygen sensor in place. Using a spanner tighten 1¼ turns only. 8. Re-fit the electrical connector. 9.
Replacing the Evaporator The evaporator should be replaced if error codes 10, 58, 59, 60, 61, or 62 occur repetitively. In general, you should check and/or replace the FID and oxygen sensor before deciding to replace the evaporator. To replace the evaporator: 1. Remove the FID. 2. Remove the glow plug. 3. Turn off the WhisperGen fuel valve. ON FUEL OFF Personal Power Station R ON FUEL WTL0012 OFF 4. Unscrew the fuel line fitting on top of the burner.
5. Undo the four screws on top of the evaporator. Evaporator (top view) Burner WTL0049 6. Lift the evaporator out of the burner. WTL0050 7. Place the evaporator gasket on the new evaporator, ensuring that all the holes line up.
8. Insert the new evaporator with the gasket into the burner and secure the four screws. 9. Check that the FID slides freely into the burner. If necessary, loosen the four evaporator screws and readjust the position of the evaporator before re-tightening them. 10. Refit the glow plug. 11. Reconnect the fuel line to the evaporator. Finger tighten the nut against the shoulder. Using a spanner tighten ¾ turn only. 12. Ensure that there is no leakages. 13. Refit the FID. 14. Bleed the fuel line.
Flushing the Exhaust Heat Exchanger The exhaust heat exchanger should be kept free from blockages to ensure optimum performance of the WhisperGen. In general you should flush the exhaust heat exchanger at least every 3 months. If the exhaust heat exchanger becomes blocked the performance of the WhisperGen will decrease. To flush the exhaust heat exchanger: 1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. Refer the section entitled Stopping the WhisperGen. 2.
5. Press ∨ to scroll down to heat exchanger nozzle bleed. R Hx Nozzle Bleed STANDBY STARTING RUNNING STOPPING FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 6. Press > to begin editing the heat exchanger bleed setting. 7. Press ∧ to select ON, then press < to begin flushing the exhaust heat exchanger. Flushing will continue for 10 seconds.
8. Once the heat exchanger bleed shows OFF repeat steps 6 and 7 two more times. R Hx Nozzle Bleed STANDBY STARTING RUNNING STOPPING OFF FAULT AUTOCHARGE EXT CONTROL HEAT MANAGE START STOP WTL0006 This flushes the system a total of 3 times. 9. Optional: press < repeatedly to return to the default display. You can also let the default display re-appear automatically by allowing a few minutes of inactivity on the control panel.
Trouble Shooting The WhisperGen automatically alerts the user to most errors. Errors may be faults or warnings. If a fault occurs, the WhisperGen will automatically clear the fault and attempt to restart. By default, the WhisperGen will attempt to restart once. If you wish to change this setting, contact your authorised WhisperGen agent. This section outlines faults and warnings that you may encounter and need to correct.
79 Code Error Message 12 Air supply fail Likely Cause and Recommended Action Likely cause: Air blower tachometer signal out of range, obstruction of impeller, or electrical fault. Recommended Action: Check connections and presence of any obstructions. Restart. 14 O2 sensor failure Likely cause: Absence of normal signal from oxygen sensor, or faulty oxygen sensor. Recommended Action: Check connections, replace oxygen sensor if fault continues. Restart.
Code 36 Error Message Likely Cause and Recommended Action Glowplug cct fault Likely cause: Glow plug faulty and/or glow plug fuse blown. Recommended Action: Check glow plug fuse. If the fuse is intact, replace the glow plug and restart. If the fuse is blown, replace both the glow plug and fuse. 38 Bus not charged See 20. 40 Isolator open Likely cause: Abnormal electrical condition. Recommended Action: Attempt to restart, contact an authorised WhisperGen service agent if problem reoccurs.
Code Error Message Likely Cause and Recommended Action 64 Heatup failure Likely cause: Failure to reach cranking temperature within eight minutes. Thermocouple failure or poor flame strength. Recommended Action: Check fuel level, fuel valve, and fuel filter. Check exhaust for blockage. Attempt to restart, contact an authorised WhisperGen service agent if problem reoccurs. 66 Crank failure Likely cause: Unsuccessful crank attempt, probably due to an electrical fault.
Code 83 Error Message Likely Cause and Recommended Action Battery overtemp Likely cause: Battery bank temperature too high for safe charging. Recommended Action: Check battery bank connections and ventilate battery bank compartment. Restart. 84 Clamp failed off Likely cause: Abnormal electrical condition, possibly resulting in raised battery voltage. Recommended Action: Attempt to restart, contact an authorised WhisperGen service agent if problem reoccurs.
104 Likely cause: Engine coolant hotter than normal. Recommended Action: Check coolant level. Check coolant and seawater circuits for obstructions. Check pumps for operation. 107 Likely cause: Temperature in electronics enclosure abnormally high. Recommended Action: Ensure ambient temperature is below 40°C. Ensure airflow from the base of the enclosure through to the electronics heat sink is not blocked.
Resetting the WhisperGen Resetting the control Panel 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 section(s) when removing or replacing parts. To reset the control panel: 1. Hold down < for at least six seconds. A beep will be heard and the control panel will return to the default display, indicating normal operation.
2. Remove the four screws in front of the electronics enclosure. Then remove the electronics enclosure cover. 2 Electronics Enclosure Cover ON FUEL OFF WTL0052 3. Unplug and then re-plug in the second fuse from the bottom - the fuse that has a current rating of 3A. 15 3 5 10 32A 3 WTL0053 4. 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.
Service Details Authorised WhisperGen service agents who commission and/or service the WhisperGen should fill in this section. The duplicate copy of the commissioning details should be detached and returned to your authorised service agent within 14 days of the commissioning date. Commissioning Engine Serial No. Commission Date Software Version Commission Date Customer’s Address Heat Manage Temp Setpoint Auto-charge Ext.
Duplicate Important: Transcribe details from the last page to this page. Then detach this sheet and return it to your authorised service agent within 14 days of the commissioning date. Engine Serial No. Commission Date Commission Date Customer’s Address Heat Manage Temp Setpoint Auto-charge Ext.
Servicing Date / Hours Description of Work Done Agent’s Stamp DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading R 88
Date / Hours Description of Work Done DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading DD MM YY / / Hour Meter Reading 89 R Agent’s Stamp
EC Conformity Manufacturer: Whisper Tech Ltd., 224 Armagh Street P.O.
Non-Harmonised standards BS799-2 1991 Specification for vaporising oil burners. BS5500 1997 Unfired fusion welded pressure vessels. ISO8528-10 1999 Reciprocating internal combustion engine driven alternating current generating set – Part 10: measurement of airborne noise. IEC 61000-4-2 1998 EMC Part 4: testing and measurement techniques. Section 2: electrostatic discharge test – basic EMC publication. IEC 61000-4-3 1995 EMC Part 4: testing and measurement techniques.
Index Absorption-charging 27 Air blower 8, 9 Application 3, 4, 5 Auto-charging 28 Backlighting of LCD 36 Battery bank 1, 27, 60, 64 Battery bank voltage fuse 60, 64 Bleeding coolant circuit 56 Bleeding fuel line 50 Bleeding seawater circuit 56 Bulk-charging 27, 29 Burner 2, 8, 9, 51 CE conformity 90 Charging battery bank 27 Charging stages 27 Checking battery bank connections 60 Checking coolant level 55 Checking fuel level 49 Checking in general 48 Circuit breaker 3, 4, 5 Clamp 39 Cleaning fuel filter 53 C
Operating options 16 Operating time 22 Operation 16 Oxygen sensor 8, 9, 70 Parameters 37 Parameter settings 41, 43 Pump 3, 4, 5, 50, 53, 56 Quick reference 16 Remote controlling 25 Removing enclosure lid 47 Replacing evaporator 72 Replacing FID 67 Replacing fuses 64 Replacing glow plug 62 Replacing oxygen sensor 70 Resetting control panel 81 Resetting electronics hardware 81 Safety precautions 11 Schedule for maintenance 45, 46 Seawater pump 3, 5, 56 Specifications 6, 7 Starting WhisperGen 18, 19 Stirling-c
