WhisperPower M-SC3.5 User manual

USERS MANUAL
M-SC3.5
- 3000 RPM -
Marine diesel generating set 230V / 50Hz
MasterBus controlled
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.eu V1. May 2010
Art.nr. 40261131

TABLE OF CONTENTS
2May 2010 / M-SC3.5 / EN
TABLE OF CONTENTS:
1INTRODUCTION.............................................................................................................................................................. 4
1.1 General .............................................................................................................................................................. 4
1.2 Service and maintenance................................................................................................................................... 4
1.3 Guarantee .......................................................................................................................................................... 4
1.4 Liability ............................................................................................................................................................... 5
1.5 Identification ....................................................................................................................................................... 5
1.5.1 Identification plate ..................................................................... Fout! Bladwijzer niet gedefinieerd.
2INFORMATION................................................................................................................................................................ 7
2.1 Safety ................................................................................................................................................................. 7
2.1.1 General.............................................................................................................................................. 7
2.1.2 Electrical safety ................................................................................................................................. 7
2.1.3 Earth insulation failures ..................................................................................................................... 7
2.1.4 Installation ......................................................................................................................................... 7
2.1.5 Operation........................................................................................................................................... 7
2.1.6 Fire and explosion ............................................................................................................................. 8
2.1.7 Chemicals.......................................................................................................................................... 8
2.2 Transport, lifting and storage.............................................................................................................................. 8
2.3 The M-SC3.5 ...................................................................................................................................................... 8
2.3.1 Features ............................................................................................................................................ 8
2.3.2 Remote control panel ........................................................................................................................ 9
2.3.3 Documentation .................................................................................................................................. 9
2.3.4 Accessories included in the standard ................................................................................................ 9
2.4 Components ..................................................................................................................................................... 10
2.4.1 Main components to identify............................................................................................................ 10
2.4.2 Local control panel .......................................................................................................................... 11
2.4.3 MasterView Easy remote control panel ........................................................................................... 11
2.5 Technical information ....................................................................................................................................... 11
2.5.1 AC alternator ................................................................................................................................... 11
2.5.2 Engine ............................................................................................................................................. 11
2.5.3 Control system ................................................................................................................................ 11
2.5.4 Battery charger................................................................................................................................ 12
2.5.5 Alarms and shut down ..................................................................................................................... 12
2.5.6 Fuel specification............................................................................................................................. 12
2.5.7 Oil information ................................................................................................................................. 12
2.5.8 Technical data ................................................................................................................................. 13
2.5.9 DC wiring diagrams ......................................................................................................................... 14
2.5.10 Wiring names and colours ............................................................................................................... 16
2.5.11 AC wiring diagram 230 V AC / 50 Hz............................................................................................... 17
3OPERATION.................................................................................................................................................................. 18
3.1 General ............................................................................................................................................................ 18
3.2 Operating instructions ...................................................................................................................................... 18
3.2.1 Summarised operating instructions (daily use)................................................................................ 18
3.2.2 Extended operating instructions ...................................................................................................... 18
4MAINTENANCE............................................................................................................................................................. 21
4.1 Alternator.......................................................................................................................................................... 21
4.2 Engine .............................................................................................................................................................. 21
4.2.1 Preliminary instructions ................................................................................................................... 21

TABLE OF CONTENTS
EN / M-SC3.5 / May 2010 3
4.2.2 Bleeding fuel lines ........................................................................................................................... 21
4.2.3 Valve clearance............................................................................................................................... 21
4.2.4 Replacing fuel filter .......................................................................................................................... 21
4.2.5 Cleaning oil strainer......................................................................................................................... 22
4.3 Regular maintenance ....................................................................................................................................... 22
4.3.1 Maintenance schedule..................................................................................................................... 23
4.3.2 Putting out of service ....................................................................................................................... 23
5TROUBLE SHOOTING.................................................................................................................................................. 24
5.1 Alternator/electrical faults ................................................................................................................................. 24
5.1.1 General............................................................................................................................................ 24
5.1.2 Failure or warning messages displayed on the remote control panel .............................................. 24
5.1.3 Other electrical problems................................................................................................................. 26
5.2 Engine faults..................................................................................................................................................... 28
5.2.1 General............................................................................................................................................ 28
5.2.2 Failure or warning messages displayed on the remote control panel .............................................. 28
5.2.3 Other engine related problems ........................................................................................................ 29
5.2.4 Warnings ......................................................................................................................................... 32
5.2.5 Service address............................................................................................................................... 32
5.3 Special procedures alternator........................................................................................................................... 33
5.3.1 Residual voltage check / excitation.................................................................................................. 33
5.3.2 Testing rotary rectifier diodes .......................................................................................................... 33
5.3.3 Winding resistant values.................................................................................................................. 33
5.3.4 Meggering ....................................................................................................................................... 33
5.4 Special procedures engine ............................................................................................................................... 34
5.4.1 Setting the RPM .............................................................................................................................. 34
5.4.2 Tightening torques........................................................................................................................... 34
5.4.3 Measuring exhaust backpressure.................................................................................................... 34
5.4.4 Disassembling instructions .............................................................................................................. 35
6SPARE PARTS LIST..................................................................................................................................................... 36
MAINTENANCE LOG ............................................................................................................................................................... 38

INTRODUCTION
4May 2010 / M-SC3.5 / EN
1 INTRODUCTION
1.1 GENERAL
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.
The information, specifications, illustrations and
statements contained within this publication are given with
our best intentions and are believed to be correct at
thetime of going to press.
All of the specifications, provisions and instructions
contained in this manual apply solely to standard versions
of the Whisper Power M-SC3.5 generating set.
This manual is valid for the following models:
Part
number Version Description
41200500 A M-SC3.5 / 230V 3000rpm wet
exhaust, MasterBus controlled
41200506 A M-SC3.5 / 230V 3000rpm wet
exhaust, MasterBus controlled -
ungrounded
See 1.5 for identification of the generator set. For other
models see other manuals available on our website:
www.whisperpower.eu.
Our policy is one of continued development and we
reserve the right to amend any technical information with-
out 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.
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 which
will result in severe personal injury or loss of
life.
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
Whisper Power guarantees that this generating set 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
generating sets are tested and inspected. The functioning
of this generating set 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 and are available on
request. Some aspects of our warranty scheme are given
here in more detail: The guarantee period is two years,
limited to 1000 running hours. Guarantee does not cover
failures that are caused by misuse, neglect or a faulty
installation.
Example 1. Faulty installation:
Seawater entering the engine is the most common cause
of damage to combustion engines in boats. (Both to
propulsion and generator engines.) The entry of water
must be avoided under all conditions. Be aware that the
conditions in blue water sailing can be extreme. Refer to
the installation manual for instructions but remember these
are for guidance only as many factors influence the
installation of a generator. The ultimate responsibility will
always be with the owner to ensure a safe and compliant
installation. If in doubt ask!
DAMAGE CAUSED BY THE INGRESS OF
WATER IS NEVER COVERED BY
GUARANTEE
Example 2: Misuse:
Long term running with no load or too little load can cause
the exhaust to get choked with soot or carbon. Cleaning
the exhaust is not covered by guarantee.
Example 3: Neglect
Sometimes the seal of the raw water pump starts leaking.
Mostly this begins with a little drip and slowly gets worse.
Regular visual inspection of the generator is necessary to
prevent damage to occur from a leaking water pump.
When one find serious damage after weeks of neglect
guarantee claims will not be honoured.

INTRODUCTION
EN / M-SC3.5 / May 2010 5
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. Labour necessary to complete
repairs on board a vessel executed by an authorized
service engineer is covered, but is limited to a reasonable
number of hours and reasonable rates in relation to the
actual repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a boat or for reinstallation. There is no cover for labour
needed to get access to the generator, for example to
remove equipment or bulkheads etc.
Goods to be delivered under guarantee will be invoiced.
Only after the faulty goods are returned will the invoice be
credited. Payment in advance may be required or
guaranteed by credit card. If after the faulty goods are
returned, it is indicated that the failure was not covered by
warranty a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by seawater, warranty will be refused. Freight
costs to deliver spares by normal mail or carriers is
covered under warranty. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote off
shoreareas any additional costs incurred over normal
carriage will be invoiced to the customer.
The cost for returning faulty goods is not covered under
warranty. Additional agreements could be part of the
contract of delivery.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee certificate, unauthorised repairs could lead to
further damage and violate the guarantee conditions.
Should work take place, which is not in
accordance with the guidelines, instructions
and specifications contained in this user’s
manual and the supplementary installation
manual, then damage may occur and the
generating set may not fulfil its specifications.
In all these cases the guarantee may become
invalid. Use original spareparts only!
1.4 LIABILITY
Whisper Power does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. Whisper Power does not accept
liability for damage due to use of the generator, possible
errors in the manuals and the results thereof.
Whisper Power cannot be held responsible for
damage caused by unattended running of the
generator due to the use of event based
commands.
1.5 IDENTIFICATION
Before using this generating set it is very important to
identify the set correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
generating set. Also for the daily operation of the
generating set it is necessary that the operator knows the
correct specifications.
1.5.1 Identification plate
All required identification data are on the identification
plate.
Fig. 1laat