WhisperPower W-SQ25 User manual

USERS MANUAL FOR MOBILE APPLICATIONS
W-SQ25
- 1500 RPM -
Mobile diesel generating set 230/400V / 50Hz
Digital Diesel Control
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
Nederland
Tel.: [phone]
Fax.: [phone]
www.whisperpower.eu
V1 January 2009
Art.nr. 40200621

CONTENTS
2 January 2009 / W-SQ25 for mobile applications / EN
CONTENTS:
1 INTRODUCTION.............................................................................................................................................................. 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 General.............................................................................................................................................. 5
1.5.2 Identification plate..............................................................................................................................6
2 INFORMATION ................................................................................................................................................................ 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........................................................................................................................................... 8
2.1.6 Fire and explosion.............................................................................................................................8
2.1.7 Chemicals.......................................................................................................................................... 8
2.2 Transport, lifting and storage..............................................................................................................................9
2.3 The W-SQ25 ......................................................................................................................................................9
2.3.1 Features............................................................................................................................................9
2.3.2 Remote control.................................................................................................................................. 9
2.3.3 Documentation ..................................................................................................................................9
2.4 Components..................................................................................................................................................... 10
2.4.1 Main components to identify............................................................................................................10
2.4.2 Generator control panel................................................................................................................... 12
2.4.3 Remote control panel ...................................................................................................................... 12
2.5 Technical Information....................................................................................................................................... 12
2.5.1 AC alternator ................................................................................................................................... 12
2.5.2 Engine............................................................................................................................................. 13
2.5.3 Digital Diesel Control system........................................................................................................... 13
2.5.4 Battery charger................................................................................................................................ 13
2.5.5 Alarms and shut down..................................................................................................................... 13
2.5.6 Monitoring........................................................................................................................................ 13
2.5.7 Control............................................................................................................................................. 13
2.5.8 Remote control................................................................................................................................ 14
2.5.9 Hour counter.................................................................................................................................... 14
2.5.10 Load indicator.................................................................................................................................. 14
2.5.11 Fuel specification............................................................................................................................. 14
2.5.12 Oil information ................................................................................................................................. 14
2.5.13 Cooling liquid................................................................................................................................... 14
2.5.14 Technical data................................................................................................................................. 15
2.5.15 Electrical diagram control wiring W-SQ25....................................................................................... 16
2.5.16 Terminal modes 115VAC – 230VAC - 400VAC 50Hz.....................................................................17
2.5.17 Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR..............................................18
2.5.18 AC Wiring Diagram single phase with AVR 230V Hz (Double Delta) .............................................. 19
2.5.19 Electrical diagrams radiator fan control ........................................................................................... 20

CONTENTS
EN / W-SQ25 for mobile applications / January 2009 3
3 OPERATION.................................................................................................................................................................. 21
3.1 General ............................................................................................................................................................ 21
3.2 Operating Instructions ...................................................................................................................................... 21
3.2.1 Summarised operating instructions (daily use)................................................................................ 21
3.2.2 Extended operating instructions ...................................................................................................... 21
4 MAINTENANCE............................................................................................................................................................. 23
4.1 Alternator.......................................................................................................................................................... 23
4.2 Engine.............................................................................................................................................................. 23
4.2.1 Preliminary instructions ................................................................................................................... 23
4.2.2 Bleeding fuel lines ........................................................................................................................... 23
4.2.3 Valve clearance............................................................................................................................... 23
4.2.4 Replacing fuel filter.......................................................................................................................... 24
4.2.5 Replacing oil filter............................................................................................................................ 24
4.2.6 Tensioning V-belt............................................................................................................................. 24
4.2.7 Air cleaner element.......................................................................................................................... 24
4.3 Regular maintenance....................................................................................................................................... 25
4.3.1 Maintenance schedule..................................................................................................................... 26
4.3.2 Putting out of service.......................................................................................................................26
5 TROUBLE SHOOTING.................................................................................................................................................. 27
5.1 Alternator/ electrical faults................................................................................................................................ 27
5.1.1 General............................................................................................................................................ 27
5.1.2 Trouble shooting table alternator..................................................................................................... 27
5.2 Engine faults..................................................................................................................................................... 28
5.2.1 General............................................................................................................................................ 28
5.2.2 Trouble shooting table engine.........................................................................................................29
5.2.3 Warnings ......................................................................................................................................... 31
5.2.4 Service address............................................................................................................................... 32
5.3 Special procedures alternator........................................................................................................................... 33
5.3.1 Automatic Voltage Regulator (AVR)................................................................................................ 33
5.3.2 Residual voltage check / excitation procedure (flashing)................................................................. 33
5.3.3 Testing rotary rectifier diodes .......................................................................................................... 34
5.3.4 Winding resistant values.................................................................................................................. 34
5.3.5 Meggering ....................................................................................................................................... 34
5.4 Special procedures engine............................................................................................................................... 35
5.4.1 Setting the RPM .............................................................................................................................. 35
5.4.2 Adjusting valve clearance and retightening the cylinder head bolts................................................. 35
5.4.3 Disassembling instructions.............................................................................................................. 36
6 SPARE PARTS LIST..................................................................................................................................................... 38
MAINTENANCE LOG ............................................................................................................................................................... 39

INTRODUCTION
4 January 2009 / W-SQ25 for mobile applications / EN
1 INTRODUCTION
1.1 GENERAL
The W-SQ25 Mobile 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 the
time of going to press.
All of the specifications, provisions and instructions
contained in this manual apply solely to standard versions
of the Whisper Power W-SQ25 generating set.
This manual is valid for the following models:
Part number Description
41101020 W-SQ25 230V 1500rpm
Mobile / keel cooling
41101026 W-SQ25 230V 1500rpm
Mobile / keel cooling -ungrounded
41101320 W-SQ25 230V/400V 1500rpm
Mobile / keel cooling
41101326 W-SQ25 230V/400V 1500rpm
Mobile / keel cooling -ungrounded
For other models see other manuals available on our
website: www.whisperpower.eu.
Our policy is one of continued development and we re-
serve the right to amend any technical information without
prior notice.
Whilst every effort is made to ensure the accuracy of the
particulars contained within this publication neither the
manufacturer, distributor, or dealer in any circumstances
shall be held liable for any inaccuracy or the
consequences thereof.
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.
DANGER
Realise that people are not used to have
230V/400V available on a vehicle. Put
warning signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
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 well 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
are available on request. The guarantee period is two
years, limited to 1000 running hours. Some aspects of our
guarantee scheme are given here in more detail:
Guarantee does not cover failures that are caused by
misuse, neglect or a faulty installation.
Example 1. Faulty installation:
Overheating of the engine or alternator is the most
common cause of problems with mobile generating sets.
These problems are caused by poor circulation of the
cooling liquid due to wrong routing of the pipes to the
radiator: bents will capture air bubbles causing “air-lockes”
blocking the circulation of the liquid. Other examples of
installation problems are hot air circulation into the radiator

INTRODUCTION
EN / W-SQ25 for mobile applications / January 2009 5
and the radiator fan sucking exhaust gasses into the
radiators.
The generator and other parts should be protected against
the influences of the weather and splashing water (with dirt
and salt) below the vehicle. 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!
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
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 vehicle or for reinstallation. There is no cover for
labour needed to get access to the generator, for example
to remove equipment or parts of the vehicle body 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
guarantee a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by water, guarantee will be refused.
Freight costs to deliver spares by normal mail or carriers is
covered under guarantee. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote areas any
additional costs incurred over normal carriage will be
invoiced to the customer.
The cost for returning faulty goods is not covered under
guarantee.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee conditions, 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.
Automatic start/stop
Whisper Power cannot be held responsible for
damage caused by the unattended running generator
using the auto-start/stop mode or interval mode.
1.5 IDENTIFICATION
1.5.1 General
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 genera-
ting set it is necessary that the operator knows the correct
specifications.

INTRODUCTION
6 January 2009 / W-SQ25 for mobile applications / EN
1.5.2 Identification plate
All required identification data are on the identification
plate. For location of the identification plate see figure 1
Fig. 1: Identification plate.
Fig. 2: Location identification plate.
1 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:
2 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 the
nominal power as shown on the identification plate.
Power is rated at an ambient temperature of 25ºC.
For higher temperatures the generating set has to be
derated. To drive the radiator fan (230 V fan) output
could be taken from power generated by the genset.
In that case net power will be less than specified on
the identification plate
3 VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency. The W-SQ25 can be
connected for different voltages in single phase or tri
phase. The nameplate indicates the connection as
made in the factory; BE AWARE THAT THE
CONNECTIONS COULD BE RECONNECTED BY
FORMER USERS
4 FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 50 Hz correlates with
1500 rpm.
5 CURRENT. This shows the maximum current that is
acceptable at the specified frequency, voltage and
power factor. When connected in tri phase the
indicated current is the current between two phases
that can be taken off three times.
6 WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and
external installation equipment
7 CE-marking: the “CE” symbol shows that the
generating set is build according to European
Community safety regulations. This includes the
regulations regarding safety of machinery, electric
safety and electric magnetic compatibility (EMC) and
other relevant directives.
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
Before changing a factory setting you are advised to
consult the manufacturer. When the generating set you
have to identify is not new you have to take into account
the possibility that former users may have changed the
settings. Check the settings (voltage, frequency, rpm)
when there is any doubt.

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 7
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.
DANGER
Warning signs draw 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.
Circumstances could make it also necessary to take
additional measures. Be aware of wet conditions and
hazardous environments caused by explosive gases etc
2.1.2 Electrical safety
This warning sign indicates parts which could
be live. The voltage of 230V or 230V/400V
generated by this generating set is dangerous
and if instructions and procedures are not
strictly observed may result in electrical shock
which will result in severe personal injury or
loss of life.
Realise that people are not used to have
230V/400V available on a vehicle. Put
warning signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
•Check all wiring at least once a year. Defects,
such as loose connections, burned cables etc.
must be repaired immediately.
•Do not work on the electrical system if it is still
connected to a current source. Only allow
changes in your electrical system to be carried
out by qualified electricians.
•Connection and protection must be done in
accordance with local standards.
•Using the auto-start/stop (interval) mode the
generator can start unexpectedly. When
working on the electrical system, the 3 Amp
fuse must be removed from the control panel
and the battery plus cable must be removed
from the battery.
2.1.3 Earth insulation failures
According to local regulations and depending on the
application it could be necessary to take measures for
protection against earth insulation failures.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral (N) and all phase lines (L1, L2
and L3). Of course this is the case when using
a Mastervolt Mass Systemswitch.
2.1.4 Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas. Installation
includes measures to be taken to outlet exhaust fumes
which contain carbon monoxide and are extremely
dangerous. Carbon monoxide (CO) is an invisible
odourless gas. Inhalation produces headache, nausea or
death. Installation includes measures for proper
ventilation, safe electric connections, safe installation of
the starting battery, proper fitting of the cooling system and
fuel pipes etc. Refer to the installation manual.
Do not use the generator set when the vehicle
is inside a building or in other enclosed area’s.
Be aware using the generator in wind still
conditions, when the exhaust fumes could
accumulate under, around or even in the
vehicle.

INFORMATION
8 January 2009 / W-SQ25 for mobile applications / EN
2.1.5 Operation
External moving parts like fans and V-belts are covered by
the soundshield and therefore the W-SQ25 is very safe
when the soundshield is closed.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
When service has to be carried out while the
engine is running, be aware of moving parts
like V-belts.
•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.
•Do not attempt to operate the generating set with
a known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.
•Always consult the manual before carrying out
maintenance.
•Do not change the settings without consulting the
manufacturer. Keep a record of setting changes
in this manual.
2.1.6 Fire and explosion
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
•Avoid refilling the fuel tank while the engine is
running. When oil or fuel is leaking do not use the
generating set.
•Do not run the engine close to explosives or
gasses.
•Hydrogen gas generated by charging batteries is
explosive. Ensure for proper ventilation. Do not
smoke or allow sparks, flames, or other sources
of ignition around batteries.
•Keep a fire extinguisher on hand.
INCASEOFFIRE, DONOTOPENSOUNDSHIELD.
TOAVOIDSERIOUSINJURYORDEATHFROMFIRE
IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS
SHUTDOWNENGINES, GENERATORSETSANDBLOWERS.
PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT.
THROUGH
HERE
FIREEXTINGUISHERPORT:
BREAK
Fig. 3: Fire extinguisher port.
•In case of fire do not open the soundshield. To
avoid serious injury or death from fire, shut down
engines, generator sets and blowers. Break
through the label which is indicated by BREAK
THROUGH HERE and then immediately
discharge entire contents of gaseous portable fire
extinguisher through the fire extinguisher port. On
the generating set this fire extinguisher port is
indicated by the label as shown in figure 3.
•Poor electrical connections or using wiring which
is not suited for the rated currents can cause
overheating and possibly fire.
2.1.7 Chemicals
•Fuels, oils, coolants, and battery electrolyte can
be hazardous to personnel if not treated properly.
Do not swallow or have skin contact with these
liquids. Do not wear clothing that has been
contaminated by fuel or lubricating oil.
•Gaskets may be manufactured from asbestos.
Particles of this material should not be inhaled as
this may result in fatal diseases.
•On no account allow any unprotected skin to
come into contact with the injector spray as the
fuel may enter the blood stream with fatal results.

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 9
•Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material.
When exposed to abnormal high temperatures in
excess of 400°C an extremely corrosive acid is
produced which cannot be removed from the
skin. If signs of decomposition are evident, or if in
doubt, always wear disposable heavy duty
gloves.
2.2 TRANSPORT, LIFTING AND STORAGE
When lifting the generating set avoid any risk
of personal injuries, do not stand under the
generating set.
•Use soft slings to avoid damage
•On the engine are two hoist eyes which can be
used to take the generator out of the capsule.
They can also be used to lift the complete
generating set including the capsule.
•After transporting the generating set check for
damage before installation.
•Long term storage can have detrimental effects
on engine and alternator. The engine should be
put through an engine preservation procedure.
(Refer to the maintenance chapter)
•The alternator windings tend to condense. To
minimise condensation, store the generating set
in a dry and warm storage area.
•After removing the generating set from long term
storage perform an insulation check. (Refer to the
alternator maintenance paragraph for
procedures)
•While the battery is stored it should be recharged
every 12 weeks.
2.3 THE W-SQ25
2.3.1 Features
This generating set includes a 4 cylinder diesel engine
which is connected by close coupling to a tri phase
synchronous alternator in a sound attenuated capsule.
The set is mounted on a steel base frame and mounted
securely on anti vibration mounting pads to the capsule
base. The complete set is again on rubber mountings. All
cables and hoses are guided through the capsule’s sides.
The set is not self contained and is only operable after
proper installation using additional accessories and
installation materials
Installation accessories are listed in the installation manual
and are available through the supplier of the generating
set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored (refer to
Digital Diesel Control users manual).
2.3.2 Remote control
The full automatic remote control panel including 15 mtr
cable comes as standard with the Whisper generating set.
2.3.3 Documentation
Included in the delivery are:
•This users manual (number: 40200621)
•An installation manual (number: 40200611)
•A users manual for DCC (number: 40200261).
•A quick reference guide for DDC (number
50200275)
Not included in the standard delivery but available as
options are:
•Parts manual; number: 40200187
•Workshop manual; number: 40200174
However in this manual there is a list of important parts for
maintenance and spare parts as well as a chapter on
maintenance and problem solving.
All manuals are available on our web site
www.whisperpower.eu.

INFORMATION
10 January 2009 / W-SQ25 for mobile applications / EN
2.4 COMPONENTS
2.4.1 Main components to identify
Fig. 4: Left View main components W-SQ25
Fig. 5 Top View main components W-SQ25
15 Filler cap engine oil
16 Filler cap engine coolant
17 Rubber engine mounting
18 Rocker cover
01 Thermostat housing
02 Boiler connection
03 Engine coolant pump
04 V-belt
05 Exhaust connection
06 Engine coolant OUT
07 Battery +
08 Battery -
09 Fuel out
10 Fuel in
11 Engine coolant IN
12 Rubber engine mounting

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 11
Fig. 6 Front View main components W-SQ25.
Fig. 7: Rear View main components W-SQ25.
19 Hoist eye rear
20 Engine speed adjusting
screw
21 Fuel injector
22 Glowplug (4x)
23 Fuel filter
24 Fuses
25 Control panel
26 Air cleaner element
27 Indentification plate
28 Oil sump handpump
29 Coolant drain plug
30 Engine oil dipstick
31 Fuel solenoid
32 Oil filter
33 Injection pump air bleeding
screw
34 Fuel lift pump for manual
priming
35 Fuel injection pump
37 Temperature switch
38 Hoist eye front
39 Alternator
40 Exhaust manifold
(watercooled)
41 Hoist eye alternator
42 Digital Diesel Control (DDC)
43 Expansion tank
44 Power take off hydro pump
45 Remote control
46 AC power output
48 Coolant injection bend
49 Engine oil pressure switch
50 Starter motor solenoid
51 Starter motor
52 Engine serial number (above
starter motor solenoid)
53 Automatic voltage regulator
(AVR)

INFORMATION
12 January 2009 / W-SQ25 for mobile applications / EN
2.4.2 Generator control panel
Start/ Stop
Removefuse
Internal fuel pump
Fuse3A
beforemaintenance
Digital Diesel Control
Fuse3A
Auxiliary
Fuse10A External Fuel Pump Fuse3A
Observeinstructionsinthemanual
Replacefuseswithsame typeandrating
Whisper Digital Diesel OperationUnit
Fig: 8 Control panel.
Fig. 9 Digital Diesel Control unit
2.4.3 Remote control panel
04
03
02
01
05 07 06
01 Generator load indicator
02 Failure LED
03 Start button
04 Stop button
05 Display
06 Select button
07 Set button
Fig. 10: Digital Diesel remote control panel
2.5 TECHNICAL INFORMATION
2.5.1 AC alternator
The tri phase synchronous alternator is directly coupled,
one bearing, brushless, rotating field design, 12 wire, four
pole (1500 RPM) and regulated by an Automatic Voltage
Regulator (AVR).
The exciter stator has a residual magnetism, which
guarantees self-exciting of the generator on start-up (that
thereby generates a residual voltage of about 10%
nominal voltage).
The AVR, powered by an auxiliary circuit on the main
stator, acts on the exciter stator indirectly controlling the
field generated by the main rotor by means of the
sequence exciter rotor - diode bridge - main rotor.
The voltage regulator controls and keeps constant the
average voltage of one phase. The voltage setting on the
AVR can be adjusted with the help of a trimmer “V”
between 185 and 290 Volts. (See par. 5.3.1)
A frequency control progressively deactivates the machine
when the drive motor speed drops below a pre-set,
adjustable threshold preventing over-excitement at low
operating speeds and abating the load engage effects on
the engine.
The AVR works only within limits of the set frequency 50
Hz. When operating below the lower limit of 46 Hz ± 1 Hz
the AVR will stop regulating to avoid overloading the
exciter coil (This setting can be changed with trimmer
“UF”). (See par. 5.3.1)
When applying the generator set at 60 Hz the AVR is re-
adjustable as well. To operate at 60 Hz the engine RPM
and Digital Diesel Control settings must also be changed.
For the USA market a dedicated manual (Art. No
50200444) is available for 60 Hz applications. Please refer
to the Whisper Power centre for specific instructions to
convert the generating set to 60 Hz.
A further option is to readjust the stability of the regulator.
In the event of very irregular (alternating) loads it could be
necessary to change this setting with the help of trimmer
“S” to avoid interference of the regulator and the
alternating load. In conclusion the regulator reaction time
can be modulated to eliminate any voltage instability that
may arise. (See par.5.3.1)
Fig. 11 Automatic Voltage Regulator (AVR).

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 13
Fig. 12 AVR Trimmers (potentiometers).
The power comes from 12 wires that can be connected in
star, delta or combined double / star and double / delta
arrangements to take off different voltages. For tri phase
400V use, the alternator should be connected in star. For
single voltage 230V use the wires should be connected in
double delta. The alternator is specially designed that in
this way one can take off the full power off the generator.
However the use of three groups of 230 V taken from the
three corners of a single delta arrangement is
recommended. Other voltages (115 Volt) can be arranged
as well. Further technical data on the connections of the
alternator can be found in drawings and diagrams in this
manual.
2.5.2 Engine
The W-SQ25 generating set is based on the Mitsubishi
S4S 4 cylinder 4 stroke diesel engine. The engine is
indirectly injected. The engine is water cooled and the
cooling liquid is cooled by a radiator.
The engine has been specially adapted for the Whisper
Power application and is very different from the standard
engine supplied for industrial applications!
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) is available
as option. Check your identification data to determine
which system is applied. The system is designed
according to the "energise to run" system. The Digital
Diesel Control is a very advanced microprocessor based
full automatic system. Besides automatic start the system
offers many monitoring options. Refer to the separate
Digital Diesel Control users manual.
The microprocessor unit is located in the black box on top
of the alternator (see figure 7)
2.5.4 Battery charger
On the engine is an alternator generating 50 Amp 12V.
This current is rectified to charge the battery. The voltage
is regulated at ±14.4V.
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the
failure light, details will be shown on the display and the
engine will be shut down. There are two functions
guarded: oil pressure and coolant temperature.
All alarm switches are closed when no malfunction occurs.
A contact is cut in the event of an alarm. This means that
the generating set will not work when the alarm switches
are broken or there is a loose wire. The system therefore
is intrinsically safe. The panel will display details about the
alarm.
2.5.6 Monitoring
Refer to the operating of the Digital Diesel Control
2.5.7 Control
The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the START button the control system is activated
and will start the engine automatically. Pushing the STOP
button will stop the engine and the electrical system will be
deactivated.

INFORMATION
14 January 2009 / W-SQ25 for mobile applications / EN
2.5.8 Remote control
All wiring connections from the remote control to the board
are made by plug in connectors.
An intermediate communication cable is in the standard
supply. If necessary an optional longer 8 wire
communication cable can be connected if the standard
length does not suit the required distance. Numerous
remote control units can be put in parallel by using the
connectors on the back of the units. (Refer to installation
instructions)
2.5.9 Hour counter
The remote control offers several timer functions that
helps to schedule maintenance.
2.5.10 Load indicator
On the remote control the load will be indicated on the
display and by the LED-bar. The load is measured by
current transformers on the alternator. All phases are
monitored and overload of all phases or just one or two
phases will provoke an alarm or even shut down when the
alarm is ignored.
2.5.11 Fuel specification
The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost importance.
2.5.12 Oil information
1 Specification:
The oil must be suitable for oil changes as specified in
the maintenance chapter. The Mitsubishi engine must
be run on heavy duty lubricating oil meeting the
requirements of API class CD, CF or CF_4.
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.
2 Oil viscosity:
We recommend a multigrade oil 15W40.
3 Oil capacity:
Excluding the oil filter the content of the crankcase is
9 l. Including the oil filter it is 9.3 l.
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance
4 Oil pressure
•Minimum at idle 98 kPa (1 kgf/cm²/14psi) (1 bar).
•At 2230 rpm ±300 kPa (3 kgf/cm²/45 psi) (3 bar).
2.5.13 Cooling liquid
The engine is cooled by cooling liquid. The capacity of this
system depends on the size of the radiator piping and
other parts in the cooling system
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling liquid
protects the engine against frost to minus 25° C. Also it
protects the engine block against corrosion. Initially one
can fill the engine via the filling cap on the exhaust
manifold. Fill up till the level is just below the filling cap.
Additional filling of engine cooling system has to be done
via the expansion tank. When the engine is on
temperature the liquid will expand and the redundant liquid
will be pressed into the expansion tank. This tank has to
be filled up till the mark. On the tank is an overflow
connection. This connection can be used to connect an
open hose to drain the overflow of the cooling liquid to
outside the vehicle.
When cooling liquid is not available clean fresh water
could be used with an additive of anti freeze. When using
water with anti freeze the right mixture has to be
calculated according to the information of the supplier of
the anti freeze.
The cooling liquid in the engine is pressurised. A high
pressure hose connects the manifold to the expansion
tank.

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 15
2.5.14 Technical data
GENERAL
Model W-SQ25
RPM 1500
Alternator 3 phase synchronous (air cooled)
Engine Mitsubishi diesel, model S4S (Japan)
Number of cylinders 4
Displacement 3331 cm3
Bore X stroke 94x120 mm
Combustion air consumption 10 m³/min.
Continuous power engine 25 kW electric power
Cooling system By means of a radiator.
Fuel lift pump engine Mechanical pump, additional electrical pump available upon request
Starting battery (optional) 110 Ah 12V
Fuel consumption 2-9 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 230/400V 50 Hz alternating current (AC) tri phase re-connectable to take off single
phase or dual voltage
Output rating Whisper 25kVA at powerfactor cos phi = 1
Voltage tolerance ± 2% (balanced load)
Frequency tolerance ± 3%
Alternator Air cooled, brushless, four pole, twelve wire, synchronous
Voltage regulation: AVR
MECHANICAL SPECIFICATIONS
Supply includes Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator
set without sound shield is optional)
Dimensions in sound shield hxwxd 126x68x80 cm
Dimensions without sound shield 115x60x75 cm
Colour Metallic silver / grey
Weight with sound shield 580 kg
Weight without sound shield 480 kg
Max. installation angle 25 degrees
Standard supplies Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation
manuals
Available as option: Installation kits, mobile (vehicle) version, non earth return, spare part kits, PTO to
drive hydraulic pump

INFORMATION
16 January 2009 / W-SQ25 for mobile applications / EN
2.5.15 Electrical diagram control wiring W-SQ25
Fig. 13 Electrical Diagram control wiring W-SQ25 for mobile applications
Optional control for two speeds fans. See chapter 4.8

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 17
2.5.16 Terminal modes 115VAC – 230VAC - 400VAC 50Hz
Fig. 14 Terminal modes W-SQ25

INFORMATION
18 January 2009 / W-SQ25 for mobile applications / EN
2.5.17 Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR
*
REFERTO2.1.3 USERMANUALWHISPER25U
* TOCONNECTNEUTRALTOGROUND
Fig 15. Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR

INFORMATION
EN / W-SQ25 for mobile applications / January 2009 19
2.5.18 AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)
* TOCONNECTNEUTRALTOGROUND
REFERTO2.1.3USERMANUALWHISPER25U
Fig 16. AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)

INFORMATION
20 January 2009 / W-SQ25 for mobile applications / EN
2.5.19 Electrical diagrams radiator fan control
DIMENTION BOX: 270x270x180 MM
JUNCTION BOX AIR FANS
12VDC K1 K2
230/115VAC
200VA
TRAFO
230VAC
Fig. 18: Electrical diagram fan control using a 230V
AC radiator fan – with two speeds fans (optional)
Fig. 17: Electrical diagram for standard fan control
using a 230V AC radiator fan