WhisperGen PPS16 User manual

user’s manual
Part Number: WP-5012-001-01

Whisper Tech reserves the right to revise or change product specifications at
any time. 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, Personal Power Station, and WhisperGen
Personal Power Station are registered trademarks of Whisper Tech Limited.
Title User's Manual - Models PPS16-12MD, PPS16-24MD
Part No. WP-5012-001-01
Application WhisperGen PPS16-12MD
Diesel fired
12 V DC output
Marine
WhisperGen PPS16-24MD
Diesel fired
24 V DC output
Marine
WhisperGen is designed and manufactured by
Whisper Tech
224 Armagh St
P O Box 13-705
Christchurch
New Zealand
www.whispergen.com
Copyright ©2005 Whisper Tech Limited
All Rights Reserved
Printed in New Zealand

Conditions of use
Read this manual completely before installing or
operating the WhisperGen
TM
.
The WhisperGen
TM
must be commissioned only by an
authorised WhisperGen
TM
representative. Whisper Tech
accepts no liability for personal injury or property damage
resulting from incorrect or unauthorised installation,
commissioning and servicing of the WhisperGen
TM
.
Unapproved installations may be dangerous, result in poor
performance and void any WhisperGen
TM
warranty.
Along with any warnings, instructions and procedures in
this manual, the user should also observe any such other
common sense procedures generally applicable to
equipment of this type.
Failure by the user to comply with any warnings,
instructions, procedures, or any such other common sense
procedures may result in injury, equipment damage,
property damage or poor performance of the
WhisperGen
TM
. The major hazards involved with operating
the WhisperGen
TM
include explosion, fire, carbon monoxide
fumes and electrical shock. These hazards can be avoided
if the user adheres to the procedures in this manual and
exercises all due care.
Whisper Tech accepts no liability for direct, indirect,
incidental, special, or consequential damages resulting
from failure by the user, installer or service technician to
follow any warnings, instructions and procedures in this
manual, or any such other common sense procedures
generally applicable to equipment of this type. The
foregoing limitation extends to damages to person or
property caused by the WhisperGen
TM
, or damages
resulting from the inability to use the WhisperGen
TM
,
including loss of profits, loss of products, loss of power
supply, the cost of arranging an alternative power supply
and loss of time, whether incurred by the user, its
employees, the installer, a service technician or any third
party.
Whisper Tech reserves the right to change the
specifications of its products, or the information in this
manual, without necessarily notifying its users.
Variations in installation and operating conditions may
affect the WhisperGen
TM
’s performance. Whisper Tech has
no control over each installation's unique operating
environment. Hence, Whisper Tech makes no
representations or warranties concerning the performance
of the WhisperGen
TM
under the actual operating conditions
prevailing at the installation. All operating parameters for
each application should be validated by a technical expert
of the user’s choosing.
Whisper Tech has made every effort to explain all
installation, commissioning, operating, maintenance,
troubleshooting procedures, warnings and safety
precautions as clearly and completely as possible.
However, due to the range of operating environments it is
not possible to anticipate every issue that may arise.
Therefore, Whisper Tech is not able to guarantee that this
manual will address every issue that may arise. This
manual is intended to provide general guidance. For
specific guidance and technical support, contact your
authorised WhisperGen
TM
supplier.
Information in this manual shall not be deemed a warranty,
representation or guarantee. For warranty provisions
applicable to your WhisperGen
TM
, please refer to the
warranty provided by the supplier of your WhisperGen
TM
.
Unless otherwise noted, reference to brand names, product
names or trademarks constitute the intellectual property of
the owner thereof. Subject to your right to use the
WhisperGen
TM
, Whisper Tech does not convey any right,
title or interest in its intellectual property, including, without
limitation, its patents, copyrights and know-how.
No part of this manual may be reproduced or transmitted in
any form or by any means without the express written
permission of Whisper Tech.
Every effort has been made to ensure the accuracy of this
document, however it may contain technical inaccuracies
or typographical errors. Whisper Tech assumes no
responsibility for and disclaims all liability of such
inaccuracies, errors, or omissions in this publication.
Use of the WhisperGen
TM
shall constitute your acceptance of the conditions above

Contents
The WhisperGen................................................................................................................................................................ 1
Introduction..............................................................................................................................................................1
What It Does............................................................................................................................................................ 1
How It Works............................................................................................................................................................2
Typical Marine Application...............................................................................................................................................3
Technical Specifications .................................................................................................................................................. 4
Summary of Parts ............................................................................................................................................................. 6
Control Panel Parts........................................................................................................................................................... 7
Safety Precautions............................................................................................................................................................ 8
Operation......................................................................................................................................................................... 14
Introduction............................................................................................................................................................14
Installing the WhisperGen
TM
..................................................................................................................................14
Quick Reference - Operating Options....................................................................................................................14
Information Structure ............................................................................................................................................. 15
Starting the WhisperGen........................................................................................................................................16
Stopping the WhisperGen......................................................................................................................................18
Remote Controlling................................................................................................................................................21
Managing the Battery Bank.................................................................................................................................... 23
Managing Heat Generation....................................................................................................................................26
Clearing Faults and Warnings................................................................................................................................28
Adjusting the LCD..................................................................................................................................................30
Displaying System Information...............................................................................................................................31
Displaying Information ...........................................................................................................................................35
Editing Parameter Settings....................................................................................................................................36
Maintenance .................................................................................................................................................................... 37
Introduction............................................................................................................................................................37
Scheduled service intervals and tasks...................................................................................................................38
Removing the Enclosure Lid..................................................................................................................................39
Checking the Fuel..................................................................................................................................................40
Bleeding the Fuel Line...........................................................................................................................................41
Cleaning the Fuel Pump Filter................................................................................................................................ 43
Checking the Coolant.............................................................................................................................................45
Bleeding the Coolant Circuit...................................................................................................................................46
Checking Battery Bank Connections......................................................................................................................48
Replacing the Glow Plug........................................................................................................................................49
Replacing Fuses....................................................................................................................................................50
Replacing the FID..................................................................................................................................................53
Replacing the Oxygen Sensor...............................................................................................................................56
Replacing the Evaporator Wick..............................................................................................................................58
Replacing the Evaporator.......................................................................................................................................60
Flushing the Exhaust Heat Exchanger...................................................................................................................63
Winterising the WhisperGen ..................................................................................................................................64

Trouble Shooting ............................................................................................................................................................ 65
Procedures............................................................................................................................................................. 65
Correcting Faults....................................................................................................................................................67
Correcting Warnings..............................................................................................................................................69
Resetting the WhisperGen ............................................................................................................................................. 71
Resetting the Control Panel...................................................................................................................................71
Resetting the Electronics Hardware.......................................................................................................................71
Service Log...................................................................................................................................................................... 73
Service Log (500 hour services) ............................................................................................................................73
Service Log (1000 hour services) ..........................................................................................................................74
Service Log (2000 hour services) ..........................................................................................................................75
Compliance Information................................................................................................................................................. 76
Symbols in this manual
Symbols are used in this manual to highlight information that is critical to
the safety of people and equipment, and to the safe and correct operation
of the WhisperGen
TM
.
An extreme hazard which may result in death or injury if proper
precautions are not taken.
A reminder of safety practices or unsafe practices which could
result in personal injury or damage to associated equipment.
A reminder of safety practices or unsafe practices which could
result in damage to the WhisperGen
TM
and/or void the warranty.
Important information essential to the installation and operation
of the WhisperGen
TM
.

The WhisperGen
TM
Introduction
1
The WhisperGen
Introduction
Congratulations on purchasing a WhisperGen
TM
PPS16.
This manual is designed to allow you to quickly learn how to safely operate
your WhisperGen
TM
. Please keep this manual for future reference and read
it before operating or maintaining your WhisperGen
TM
.
In this manual, warnings against hazards are marked with the
symbol shown on the left. Heed all warnings at all times.
For information regarding the standard kit items that are supplied with each
WhisperGen
TM
, and if you have any questions or suggestions, feel free to
contact your authorised WhisperGen
TM
agent.
In some countries, it is a legal requirement that this manual must be
permanently placed alongside the WhisperGen
TM
and maintained in a
readable condition. Check with your local authority about this requirement.
What It Does
The WhisperGen
TM
PPS16 is a Personal Power Station that generates
heat and electrical energy simultaneously.
The WhisperGen
TM
PPS16 is capable of charging and managing a
lead-acid battery bank to provide a DC electrical power supply.
The WhisperGen
TM
PPS16 also provides heat energy in the form of hot
coolant for space heating and domestic hot water generation.
ELECTRICAL
APPLIANCES
·
Refrigerator
·
Washing Machine
·
Microwave
·
Video Recorder
·
Television
·
etc.
INVERTER
(Converts DC
to AC)
+ ?
BATTERY
BANK
DCAPPLIANCES
(12 or 24 Volt DC)
Electricity
(DC)
WHISPERGEN
Coolant
HOT
WATER
CYLINDER
HEATER
Personal Power Station
ON
OFFFUEL
WTL0001
R
Note: Not all elements of the actual system are shown in this schematic.
TM

How It Works The WhisperGen
TM
2
How It Works
The WhisperGen
TM
onboard heat and power system 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.
The nitrogen gas is heated by a continuous-combustion burner, and cooled
by coolant circulating through engine cavities. Heat transferred to the
coolant can be used to heat domestic water cylinders and for space
heating.
The burner consumes air and fuel. The flow rate of air and fuel into the
burner is optimised by a microcomputer. This maximises combustion
efficiency and minimises exhaust emissions.
The microcomputer automatically controls all WhisperGen
TM
functions and
displays real-time information about the system on a control panel from
which the user can also alter operating options.
WTL0002

Typical Marine Application How It Works
3
Typical Marine Application
9
1
7
8
2
3
4
56
Number Description
1 WhisperGen
TM
2 Battery Bank
3 DC/AC inverter
4 Standard domestic appliances
5 Hot water for domestic use
6 Space heating
7 Excess heat removal
8 12 or 24 V equipment
9 Cool exhaust vent

How It Works Technical Specifications
4
Technical Specifications
Feature Specification Remark
Prime mover 4-cylinder Stirling-cycle
engine pressurised to 28
bar with nitrogen.
Closed thermodynamic
cycle.
Power output Co-generation of heat and
electricity.
Heat 5.5kW useable heat
(up to 6.5kW in heating
mode).
Heat output depends on
operating conditions.
Electrical 800W electrical. Gross output depends
on operating conditions.
Duty cycle 1 to 24 hours per day.
Fuel **
Type Diesel: EN590; BS2869:
2000 Class A2, D. Minimum flash point, closed, 56°C.
Consumption Less than 1 litre per hour. At nominal power output.
Control
Manual Manual start/stop from
control panel.
External Optional remote starting via
external switch. Timer, thermostat, or on/off switch may be
used.
Auto-charge Optional automatic battery
bank charging. Starts and stops at preset discharge levels.
Heat
management Optional automatic heat generation to maintain
coolant temperature.
Coolant temperature is
user-selectable.
External heater Optional control of an
external heater to boost and
maintain coolant
temperature.
Coolant temperature is
user-selectable.
Electrical **
Nominal voltage 12V or 24V DC.
Battery bank
capacity 12V: 200Ah minimum recommended.
24V: 100Ah minimum
recommended.
Battery bank not
included in standard kit.
Battery bank
charging 3-stage charging on each run: bulk, absorption, and
float.
Battery bank voltage,
current, and Amp-hours
monitored and displayed
on control panel.
** Machine type is set at the factory

Technical Specifications How It Works
5
Feature
Specification Remark
Cooling
system
Primary Cooling:
High quality marine grade
glycol-based corrosion-
inhibited anti-freeze for
freezing conditions.
Clean distilled water and high-
quality marine-grade
corrosion-inhibitor, suitable for
use with aluminium.
Removes heat from
engine.
Heat is transferred to
hot water cylinder(s)
and space heater(s).
Cooling method
Secondary Cooling:
Water-cooling (marine
applications).
Raw water cooling.
Heat
exchangers Internal exhaust and marine heat exchangers. Requires external coolant pump and
seawater pump.
Exhaust
temperature 80°C nominal, 95°C maximum. Cooling system extracts heat from exhaust.
Connections
All connections
provided on the rear
panel of the enclosure.
Fuel Rp 1/8 (ISO 7-1). BSPP 1/8
Heat
exchangers Rp 3/4 (ISO 7-1). BSPP 3/4
Exhaust Rp 1 1/4 (ISO 7-1). Exhaust must be vented
outside occupied areas.
Exhaust flushing G 3/4 (ISO 228-1). Face sealing fitting
required.
Condensate
draining 12.7mm O.D. plain tube.
Battery bank 50mm² screw terminals.
External switch 0.5 to 2.5mm² screw
terminals.
PC RJ 45. Via RS485-to-RS232
converter.
Physical
Dimensions 450mm (W) x 500mm (D) x
650mm (H).
Dry weight 90kg.
Environmental
Temperature/
humidity -10°C to 40°C. 99% RH, non- condensing. With suitable fuel and coolants.

How It Works Summary of Parts
6
Summary of Parts
2
FUEL OFF
ON
Personal Power Station
FAULT
A
UTOCHARGE
EXTCONTROL
HEAT MANAGESTOPPING
RUNNING
STARTING
STANDBY
STOP
START
R
R
1
7
8
9
234
5
6
10
Number Description
1 Fuel evaporator assembly
2 Air intake
3 Burner assembly
4 Exhaust heat exchanger
5 Lifting lug
6 Terminal block
7 Electronics enclosure
8 Main enclosure (cover)
9 Fuel valve
10 User control panel

Control Panel Parts How It Works
7
Control Panel Parts
R
1
2
3
4
Number Name Function
1 START Key The key that:
(a) Starts up the WhisperGen
TM
;
(b) Begins battery bank bulk-charging; and
(c) Clears faults.
2 SELECT
Keys The arrow keys that provide access to system menus for;
(a) Information display; and
(b) Editing system parameters.
3 STOP Key The key that shuts down the WhisperGen
TM
.
4 Indicators The lights that indicate the status of the
WhisperGen
TM
system.
STANDBY: the WhisperGen
TM
is ready to start.
STARTING: the WhisperGen
TM
is starting.
RUNNING: the WhisperGen
TM
is operating.
STOPPING: the WhisperGen
TM
is stopping.
FAULT: a fault or warning is present.
AUTOCHARGE: the battery bank auto-charging
function is turned on.
EXT CONTROL: external control of the
WhisperGen
TM
is enabled.
HEAT MANAGE: the heat management
function is turned on.
5 LCD Display A liquid-crystal display that shows system
information such as charging current, battery
bank voltage, power output, etc.

How It Works Safety Precautions
8
Safety Precautions
Please read and understand this section ENTIRELY before operating or
maintaining the WhisperGen
TM
. Not heeding the warnings or
recommendations could damage the WhisperGen
TM
, cause personal injury,
and/or void the warranty.
This manual must be permanently placed alongside the WhisperGen
TM
and
maintained in a readable condition.
FUEL OFF
ON
WTL0015
PersonalPo wer Station
The WhisperGen
TM
is a pressurised device and must be installed and
serviced by an authorised WhisperGen
TM
service agent. Incorrect
installation or servicing can damage the WhisperGen
TM
and property, cause
personal injury, and/or void the warranty.
Always heed warning signs on the WhisperGen
TM
. The engine contains
high-pressure nitrogen and some internal surfaces are hot.
FUEL OFF
ON
Critical Applications
Other
Supply
WTL0016
Persona lP ow er Station
Never use the WhisperGen
TM
as the sole source of electrical power for
critical applications.
FUEL OFF
ON
WTL0017
Personal Pow er Station
The WhisperGen
TM
should be pressurised by an authorised service agent
only. Do not do it yourself and do not adjust the pressure relief valve.

Safety Precautions How It Works
9
F
U
EL OFF
ON
WTL0021
Persona lPowerStation
Exhaust gases from the WhisperGen
TM
should always be vented outside
closed areas. Exhaust piping in enclosed areas must be properly sealed.
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.
Do not use fuels other than the specified class of fuel as this may damage
the WhisperGen
TM
and/or cause a fire
Air bubbles present in the fuel line can cause the WhisperGen
TM
to
malfunction. Bleed the fuel line after filling a completely empty fuel tank.

How It Works Safety Precautions
10
The cooling system is vital to the performance of the WhisperGen
TM
. If
there are leakages in the cooling circuit, or the water is not flowing, inform
an authorised WhisperGen
TM
agent immediately.
Use only the recommended coolant mixture. Using an incorrect type of
coolant fluid can cause serious corrosion in the WhisperGen
TM
.
Ensure that fuel and coolant used on the WhisperGen
TM
are clean and free
of particulate contaminants. Foreign particles can obstruct fuel/coolant
passages, resulting in a malfunction or damage to the WhisperGen
TM
.
FUEL OFF
ON
Personal PowerStation
2
During normal operation of the WhisperGen
TM
, the enclosure lid and
electronics enclosure lid must be fitted.

Safety Precautions How It Works
11
FUEL OFF
ON
Per sonal Pow er Stati on
BakeTime____
123
456
789
0
OPEN START
Do not sit anything on the WhisperGen
TM
or press down hard on the top.
FUEL OFF
ON
Person alPo wer Stat ion
Do not expose the WhisperGen
TM
to large physical impacts.
FUEL OFF
ON
Personal Power Station
Do not expose the WhisperGen
TM
to excessive vibration.
FUEL OFF
ON
Personal Pow er Stat ion
Do not expose the WhisperGen
TM
to extreme temperatures. The ambient
temperature should not exceed 40°C or fall below -10°C
FUE L OFF
ON
Pers onal Pow er Stati on
Do not install, operate or store the WhisperGen
TM
in a wet or poorly
ventilated place.

How It Works Safety Precautions
12
FUEL OFF
ON
Pers onalPowerStation
Do not operate the WhisperGen
TM
in a potentially explosive environment.
FUEL OFF
ON
Personal Pow er Stat ion
Do not store rags or other items inside or beside the WhisperGen
TM
as the
air circulation through the WhisperGen
TM
may be disrupted.
FUEL OFF
ON
P erson al Pow er St ati on
Do not drill holes in the enclosure. Air circulation through the WhisperGen
TM
may be disrupted.
Do not modify the piping for the fuel, exhaust, and cooling systems of the
WhisperGen
TM
without first consulting an authorised WhisperGen
TM
agent.
FUEL OFF
ON
Personal Power Station
Isolate the WhisperGen
TM
from the battery bank before making or breaking
other connections on the battery bank.