WhisperPower Belt Power W-BD 3.5 User manual

USERS MANUAL FOR
Belt Power
belt driven generator
W-BD 3.5 / W-BD 5: 230V 50Hz
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.eu V1 June 2010
Art.nr. 40200571
V3 November 2011

CONTENTS
2November 2011 / W-BD3.5/W-BD5 BeltPower / 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..............................................................................................................................5
2 INFORMATION................................................................................................................................................................ 6
2.1 Safety................................................................................................................................................................. 6
2.1.1 General.............................................................................................................................................. 6
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 Storage...............................................................................................................................................................8
2.3 Features beltpower............................................................................................................................................. 8
2.3.1 How does it work?.............................................................................................................................8
2.3.2 Application.........................................................................................................................................9
2.4 Components....................................................................................................................................................... 9
2.4.1 Main components to identify.............................................................................................................. 9
2.5 Technical information....................................................................................................................................... 10
2.5.1 Generator ........................................................................................................................................ 10
2.5.2 Inverter............................................................................................................................................ 10
2.5.3 Alarms and shut down..................................................................................................................... 10
2.5.4 Control............................................................................................................................................. 10
2.5.5 Remote control panel ...................................................................................................................... 10
2.5.6 Display............................................................................................................................................. 10
2.5.7 Technical data................................................................................................................................. 11
2.5.8 Lay out control wiring....................................................................................................................... 12
3 OPERATION.................................................................................................................................................................. 13
3.1 General ............................................................................................................................................................ 13
3.2 Checking before use ........................................................................................................................................ 13
4 MAINTENANCE............................................................................................................................................................. 14
4.1 Generator......................................................................................................................................................... 14
4.2 Inverter box ...................................................................................................................................................... 14
5 TROUBLE SHOOTING.................................................................................................................................................. 14
5.1 Generator/electrical faults ................................................................................................................................ 14
5.1.1 General............................................................................................................................................ 14
5.1.2 Service address............................................................................................................................... 14
5.1.3 Display indication overview ............................................................................................................. 15
5.1.4 Fault finding table when the system is not working.......................................................................... 16
5.1.5 Fault finding table when the system stops working.......................................................................... 17
5.1.6 Overview display modes.................................................................................................................. 18
5.2 Special procedures generator .......................................................................................................................... 19

CONTENTS
EN / W-BD3.5/W-BD5 BeltPower / November 2011 3
5.2.1 Checking the windings..................................................................................................................... 19
6 SPARE PARTS LIST..................................................................................................................................................... 19

INTRODUCTION
4 November 2011 / W-BD3.5/W-BD5 BeltPower / EN
1 INTRODUCTION
1.1 GENERAL
The Belt Power belt driven generator makes it possible to
generate 230V 50 HZ AC Power from the main engine of a
vehicle or boat or any other engine running at variable
speed or fixed speed, to drive a specially designed
generator. A dedicated inverter inverts the variable voltage
and frequency from the generator to a smooth sine wave
output of 230V 50Hz.
The Belt Power is designed for applications on vehicles
and boats and is manufactured for and marketed by
Whisper Power.
It is important to read this manual before installing and
operating the Belt Power. Refer to the installation manual.
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 Belt Power first launched in June 2010
This manual is valid for the following models:
Part number Description
41301000
41302000 W-BD 3.5 3.5 kW, 230V 50Hz W-BD 5 5 kW, 230V 50Hz
For other models and power generation products we have
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 available on a vehicle or small boats.
Put warning signs on wall sockets and on
junction boxes. Instruct non-regular users of
the vehicle or boat. Warn maintenance
personal of garages that do service on the
vehicle or boat.
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 Belt Power generator
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 Belt
Power generators are tested and inspected.
The well functioning of this Belt Power generator 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 or 1000 running hours; whatever comes first. 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:
V-belt alignment problems are the most common cause of
problems with Belt Power generators. Incorrect alignment
of the V-belt pulleys will cause extreme wear out of the V-
belt, pulleys and generator bearings.

INTRODUCTION
EN / W-BD3.5/W-BD5 BeltPower / November 2011 5
To obtain the rated power from the generator requires
accurate calculations on engine power, rpm and pulley
diameter ratio’s for optimal generator performance.
The inverter, 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 Belt Power. 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 high load on or too low rpm cause
overheating problems and can damage the generator and
V-belt transmission.
Example 3: Neglect
Running with a loose V-belt will cause wear out and
damage from the slipping V-belt.
Guarantee means that faulty parts are repaired or
replaced free of charge. Labour necessary to complete
repairs on board a vehicle 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. Also covered is the
labour required to take an generator or inverter out of a
vehicle or for reinstallation, also limited to a reasonable
number of hours and reasonable rates.
Travel expenses and travel hours are not covered. There
is no cover for labour needed to get access to the inverter
or 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.
The cover of the inverter box should not be
removed at any time. Service at the inverter
should only be made by authorised service
stations. Unauthorised repairs and work, which is not in
accordance with the guidelines, instructions and
specifications contained in this user’s manual and in the
supplementary installation manual can cause damage. In
all these cases the guarantee may become invalid. Use
original spare parts only!
1.4 LIABILITY
Whisper Power does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the Belt Power 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 Belt Power, possible
errors in the manuals and the results thereof.
1.5 IDENTIFICATION
1.5.1 General
Before using this Belt Power it is very important to identify
the model correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
Belt Power. Also for the daily operation of the Belt Power it
is necessary that the operator knows the correct
specifications.
1.5.2 Identification plate
All required identification data are on the identification
plate of the inverter box. On the generator is an type
model referring to the generator only. For location of the
identification plates see figure 1.

INTRODUCTION
6 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
Fig. 1: Location identification plate inverter box.
Fig. 2: Identification plate inverter box.
1 The identity of the Belt Power inverter box is given by
the SERIAL NUMBER on the type plate of the inverter
box. This number is also on the first page of this users
manual. The identity of the generator is given by the
SERIAL NUMBER on the type plate of the generator.
The identification plate of the generator is on the
generator and gives the Article Number and serial
number an power rating (3.5 or 5 kW)
When this numbers are available the manufacturer
can trace the specifications of the inverter and
generator . On the identification plate are also some
basic features of the inverter and generator:
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 Belt Power has to be de-
rated.
3 VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal generator rotation speed..
4 FREQUENCY is shown in Hz and is not determined
by the speed of the engine as this is a variable peed
generator and the frequency is generated by the
inverter.
5 CURRENT (Amps) shows the maximum current that
is acceptable at the specified frequency, voltage and
power factor.
6 WEIGHT shows the weight (approximately) in kg.
This is without, packing and external installation
equipment.
7 CE-marking: the “CE” symbol shows that the Belt
Power is build according to European Community
safety regulations. This includes the Pleasure Craft
Directive, regulations regarding electric safety and
electric magnetic compatibility (EMC) and other
relevant directives. Regarding the Machinery
Directive the Belt Power is an incomplete machine
and can only comply after installation. Refer to the
Declaration included in this manual.
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 Belt Power 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, max.
load) when there is any doubt.
2 INFORMATION
2.1 SAFETY
2.1.1 General
When correctly installed and used in normal
circumstances this Belt Power fulfils EC safety regulations.
This Belt Power 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. Regarding the
Machinery Directive the Belt Power is an incomplete
machine and can only comply after installation. Refer to
the Declaration included in this manual.
Circumstances could make it also necessary
to take additional measures. Be aware of wet

INFORMATION
EN / W-BD3.5/W-BD5 BeltPower / November 2011 7
conditions and hazardous environments
caused by explosive gases etc
ATTENTION! An important safety feature is
when the inverter is automatically switched
off because of a low speed alarm and later
the speed is increased again the inverter
must me switched on again manually,
because it could be dangerous when
appliance start spontaneously such as a
saw or a drill.
However this could be very inconvenient for
other applications that are permanently
switched on. On request Whisper Power
can adjust the software to change this
feature so that the power comes back
automatically when the speed is in order
again.
2.1.2 Electrical safety
The generator output (which is the inverter
input) can be as high as 340 Volt and is very
dangerous. The only way to get access to the
high voltage parts is with the help of tools.
One should never run the Belt Power when
there is access to these parts. Contact to this
parts may result in electrical shock which will
result in severe personal injury or loss of life.
Also the 230 Volt generated by the inverter 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.
Never connect the inverter output to a 230V
connection to the public grid.
When a connection to the public grid is
required, a “shore” or “land” power source
selector switch much be installed between the
inverter and the boat’s/vehicle’s electrical
system.
Realise that people are not used to have
230V available on a vehicle or small boat. 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 or boat.
•Check all wiring at least on a monthly base. 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.
•The inverter box cannot be opened without special
tools. The cover must not be removed at any time.
Service on the electronics must only be made by
authorized personnel.
•Connection and protection must be done in
accordance with local standards.
•Extension cables must be suitable for outdoor use:
3.5 kW model: Use 16 Amp rated cable (2.5mm
2
)
maximum 100 m.
5 kW model: Use 25 Amp rated cable (4mm
2
)
maximum 100 m.
•The DC control voltage should be fused with:
Fuse: W-BD 3,5 3 Amp. And W-BD 5 12/15 Amp.
Warning signs indicate parts which could be
live.
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 and Belt Power should switch both
neutral and L1..
2.1.4 Installation
Generator and inverter are not self contained and have to
be properly installed in enclosed areas. Installation
includes measures for proper ventilation, safe electric
connections. Refer to the installation manual.
Do not use the Belt Power when the vehicle is
inside a building or in other enclosed area’s.
Be aware using the Belt Power in wind still
conditions, when the exhaust fumes could
accumulate under, around or even in the
vehicle.

INFORMATION
8 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
2.1.5 Operation
When the on/off switch is in the on-position when the
vehicle (boat) engine starts the inverter will immediately
generate 230V to the outlet. Ensure that all appliances not
intended to use are switched off or disconnected
Close to the generator will be moving parts like fans and
V-belts and hot engine parts.
Take note of the signs on the Belt Power parts
which show symbols in a triangle indicating
danger.
•The Belt Power should be operated by authorised
personnel only.
•Be aware of hot parts engine parts and especially
parts of the exhaust system and the cooling system.
•If the Belt Power is unsafe, fit danger notices and
disconnect the battery positive (+) lead of the engine
so that it cannot be started until the condition is
corrected.
•Do not attempt to operate the Belt Power with a
known unsafe condition.
•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
Engine 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 Belt
Power.
•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.
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.
2.2 STORAGE
•After transporting the Belt Power check for damage
before installation.
•Long term storage can have detrimental effects on the
generator and inverter.
•The generator windings and some electronic
components in the inverter tend to condense. To
minimise condensation, store the generator and
inverter in a dry and warm storage area.
2.3 FEATURES BELTPOWER
2.3.1 How does it work?
A special designed generator (generator) has to be
mounted on an available engine such as the main
automotive engine or propulsion engine in a boat. The
generator is driven by V-belt/pulley transmission.
The generator generates a high voltage between 200 Volt
and 340 Volt (on a very high frequency) that is converted
by a special designed inverter to a 230 Volt 50 Hz sine
wave output, independently of the rpm of the engine, with
a very high efficiency of about 94%.
There are two benefits that makes this system superior to
systems that work on low DC voltage (12V or 24V). First
high voltage means low currents and little resistant losses
and thinner cables. Secondly the inverter does not need to
transform a low battery voltage up to 230 Volt which
saves a transformer or step up module. All together the
efficiency is much higher and the installation much easier
Because of the small dimensions the Belt Power will fit
where a diesel driven generator is too big and heavy. The
most common applications are service vans, ambulances,
fire fighting vehicles and small pleasure crafts.
The inverter will often be placed in a separate
compartment where it is more protected against dirt and
humidity.
The generator speed depends on the ratio of the pulleys
and the engine speed. The pulley/belt transmission system
should be calculated and designed to keep the generator
in the RPM area where it can perform optimally. Refer to
the installation manual for more details. When necessary
one can extend the installation with an manual- or
automatic system to adapt the speed to the load applied.
Refer to the installation manual for more details.
All cables and hoses are guided through the inverter
housing and connected on a terminal board inside.
Installation accessories are listed in the installation manual
and are available through the supplier of the Belt Power.
The Digital Control system of the Belt Power is based on
microprocessor technology. The system can be controlled
and monitored from the display on the inverter casing and

INFORMATION
EN / W-BD3.5/W-BD5 BeltPower / November 2011 9
via a remote control panel. The remote control panel
includes 5 meter remote cable. 10 or 15 m cable can be
ordered as option with the Belt Power.
2.3.2 Application
The Belt Power generator is a very good solution for
vehicles and small boats that require AC power and does
not have enough space for a diesel generator. As the
inverter works independently from a battery, the
installation is not as heavy as a battery based inverter
system and is more efficient, because a fully battery based
inverter system would have a battery efficiency loss of at
least 20% and other losses for transforming the low DC to
high AC. Especially when high power is needed from 2
kW up to 5kW the Belt Power is superior.
For some applications where power is needed while the
vehicle engine cannot run or when the engine runs at a too
low speed (RPM) a combination with a battery based
inverter/charger (COMBI) system is recommended.
While the engine is not running the battery based inverter
can take care of supply and when running again the belt
driven generator can charge the batteries via the charger.
One hast to take care that both inverters can work in
parallel! Many of the latest generation combi’s can run in
parallel! The Power Belt inverter and combi could also
work together to provide extra power for short periods or
handle inrush currents for motor starting (starting up air
conditioners or compressors). The combination of both
systems does require a smaller battery than when
applying only a low DC inverter.
2.3.3 Documentation
Included in the delivery are:
•This users manual (number: 40200571)
•An installation manual (number: 40200591)
Manuals in many languages are available on our web site:
www.whisperpower.eu.
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.
2.4 COMPONENTS
2.4.1 Main components to identify
Fig. 3: Main components of the Belt Power

INFORMATION
10 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
2.5 TECHNICAL INFORMATION
The Belt Power is a very advanced high tech variable
speed electric power supply system. It is based on the
latest inverter and generator technology and offers a very
stable sinus and high efficiency.
2.5.1 Generator
The Three Phase 230V Generator (200Volt up to 340V) is
made according to a dedicated design and offers usable
power over a large frequency band. Further technical data
on the design of the generator can be found in drawings
and diagrams in this manual.
2.5.2 Inverter
To invert the variable voltage output from the generator to
230V 50Hz AC a state of the art inverter is applied. The
inverter should be mounted in an separate protected
space. Technical data are below (2.5.7).
2.5.3 Alarms and shut down
The inverter can shut down because of overheating,
overload, short circuit or low RPM.
When the RPM decrease and the load is higher than the
alternator can deliver the inverter shuts down. Then the
inverter will restart three times with 5 seconds delay. The
user or system should disconnect some load, so the
alternator and inverter is capable to deliver the power.
In case the inverter is in failure, the failure is shown on the
display and the alarm led on the inverter burns.
2.5.4 Control
The Belt Power can be operated by switch on the panel on
the inverter box or on the remote control. By switching the
switch to ON the control system is activated and will
generate electricity when the engine is running. Switching
OFF will switch off the inverter and there will be no AC
output any more. In case of a remote panel the switch
on the inverter box operates as a main switch that has
to be ON before the inverter can be switched on via
the remote panel.
The same switch can be used to switch off the Belt Power.
After a failure has switched off the inverter. It must be
manually reset by switching the OFF and ON again (either
on the inverter or on the remote) to be able to use the Belt
Power again. This could be inconvenient when the failure
is because of a too low speed situation. Specially when
the system is used in a driving vehicle the engine rpm is
depending on the speed of the vehicle.
ATTENTION! People have to be aware the
output voltage will return after shutdown.
In some applications this is not allowed and
therefore this function must be switched off by Whisper
Power.
Fig. 4: Belt Power control panel
2.5.5 Remote control panel
A remote control is available that offers the same control
and monitoring functions as are available on the inverter
box. All wiring connections from the remote control to the
Belt Power control unit 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 (Refer to
installation manual)
2.5.6 Display
Both on the inverter box as well as on the remote control
panel is a display that shows the status of the system as
well as many relevant parameters and failure indications.
By pushing the button below the display one can scroll to
different display modes. An overview of these modes is on
page 17 of this manual. The additional LED signals are
only on the inverter box and not on the remote panel.
Fig. 5: Belt Power remote control panel

INFORMATION
EN / W-BD3.5/W-BD5 BeltPower / November 2011 11
2.5.7 Technical data
GENERAL
Model W-BD 3.5/ W-BD 5
RPM/Power W-BD 3.5: 2500 rpm/1 kW, 4000 rpm up to 15000 rpm/ 3.5 kW. (Refer to diagram)
W-BD 5: 3300 rpm/1 kW, 7000 rpm up to 15000 rpm/ 5 kW. (Refer to diagram)
Continuous Power 3.5 kW /5 kW 230V 50Hz pure sine wave
Peak Power 7.5 kW/10 kW
Alarms Short circuit – overload – over-temperature - low/high rpm - low/high voltage
Fuse DC control voltage Fuse: W-BD 3,5 10 Amp. W-BD 5 12/15 Amp.
Battery Supply W-BD 3.5 12 V up to 24V self ranging; W-BD 5 only 12 V*
*When needed a small 24V to 12 V DC/DC converter can be supplied as an option
GENERATOR
Model AAN 3.5 kW/ AAN 5kW*
Power rating 3.5 kW/ 5 kW*
Max rotor voltage 14.4 V
Rotor resistance 2.85 Ω+ 0.1 Ω
Output (stator) voltage 200V-340V, 3 phase
Stator resistance
(between phases) 3.5kW: 5.3Ω+ 0.25Ω/ 5kW: 2.9Ω+ 0.25Ω*
Dimensions generator 159x178x190 mm
Weight 6.9 kg
Standard pulley Poly V 6 grove Ø60 mm; other pulleys on request, refer to the installation manual
* In some installations we recommend to apply a 5 kW generator in combination with a 3.5 kW inverter. Check the generator
type plate for identification.
INVERTER
Input Voltage 200V-340Hz, 3 phase
Output voltage 230 V + 7% single phase
Output rating 3.5 kW /5 kW at power factor cos. phi = 1
Max nominal continuous current 3.5 kW: 16 Ampere/ 5kW: 27 Ampere
Max surge current 320 ms 3.5 kW: 32 Ampere/ 5 kW: 85 Ampere
Harmonic distortion <7%
Frequency tolerance ± 0.5%
Efficiency 95%
Dimensions inverter box w x d x h 314x125x380mm
Weight inverter box 9.6 kg
Colour Metallic silver RAL9006
STANDARD SUPPLIES
Supply includes Generator, Inverter box,
OBLIGATORY EXTRA SUPPLY Shielded cable (To be choose from 3 lengths: 5, 8 or 10 m)
Including kit with installation material
OPTIONAL SUPPLIES
Optional supplies Remote control panel including cable
Installation supplies Generator pulley, drive pulley, mounting
brackets, V-belts.

INFORMATION
12 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
2.5.8 Lay out control wiring
Fig. 6: Electrical Diagram
Fuse: W-BD 3,5 3 Amp.
W-BD 5 12/15 Amp.

OPERATION
EN / W-BD3.5/W-BD5 BeltPower / November 2011 13
3 OPERATION
3.1 GENERAL
The Belt Power is operational after full installation and
connecting the remote control panel.
3.2 CHECKING BEFORE USE
Do not start the engine before thoroughly
checking the installation.
Mechanical inspection
•Check the generator and make sure that it is
securely and irremovable mounted on the engine.
•Check the pulleys and make sure that they are
parallel and aligned.
•Make sure that the belt and the pulleys can run
without obstruction.
•Make sure that the belt is tightened according to
the manufacture’s instructions.
•Make sure that the belt has sufficient clearance in
order not to damage surrounding parts at large
load changes.
•Check that the Power Box is mounted correctly:
– on a plane surface;
– in a well-ventilated area;
– protected against moisture.
•Check that the openings of the Inverter Box are
not covered.
Electrical inspection
•Make sure that all the wiring is done in a secure
and correct way.
•Make sure that all cables are undamaged,
unloaded, securely attached, not rubbed or
pinched in any way.
•Check that all cables are mounted and tightened
in a proper way.
•Check that all connectors and socket screws are
well tightened.
•Check that all appliances not intended for use are
turned off or disconnected.
•Make sure that the earth connection is correctly
installed.
Precautions before starting
Before switching on the Belt Power check:
•that appliances not intended for use are turned
off or disconnected;
•that the engine is correctly running (if not: the
green LED is flashing after switching on the
inverter.).
•that the requested/needed electrical power is
adequate for the nominal output (if not: the
Power Box starts with auto-protection, the red
LED is continuously lit).
•that the generator’s revolutions are adequate for
the requested electrical power.
(if not: the Power Box starts with auto-protection,
the red LED is continuously lit. See page 9 and
10 in the installation manual.
Starting Belt Power
•Switch on the control panel and via the remote
control if it is present. In case of a remote panel
the switch on the inverter box operates as a main
switch that hat to ne “ON” before the inverter can
be switched on via the remote panel..
•Check the LEDs of the Power Box (see chapter
“Display elements” on page 1).
•When the green LED is continuously lit switch on
the electrical load according to the nominal load
and the correspondent generator’s speed.
•By the push button on the inverter or on the
remote one can scroll between different display
modes that show information an several
parameters.
Shutting down
•Turn off all electrical appliances which shall not
start automatically when the Belt Power is
switched on again.
•Switch OFF Belt Power on the control panel or
via the remote control.

MAINTENANCE
14 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
4 MAINTENANCE
4.1 GENERATOR
Keep the generator clean and in dry condition. Check if
cooling air has free access. Check the V-belt for alignment
and for wear out (refer to figure 7). Replace when the V-belt
shows signs of wear out. The lifetime of the brushes and
bearings is strongly depending on the installation,
environmental conditions and application. In good
conditions and mild application the average life time of the
bearings is at least 6000 hours for the front bearing and
20.000 hrs for the rear bearing.
Every 1000 hours the bearings must be checked. The
average life time of the brushes is 7500 hrs. Every 1000 hrs
the brushes must be checked.
A belt too tight or too loose will reduce the life
of the belt and generator (pulley and bearings)
and will reduce the performance.
4.2 INVERTER BOX
The electronic equipment itself in the inverter box does not
require any maintenance. Keep the air inlet opening free
from dirt and blockages. The air filters inside the box are
designed for fife time use. In case of extreme polluting
conditions the filters must be changed by an authorized
service station. The inverter box cannot be opened without
special tools. The cover must not be removed at any time.
Service on the electronics must only be made by authorized
personnel.
Fig. 7: Alignment V-belt
5 TROUBLE SHOOTING
5.1 GENERATOR/ELECTRICAL FAULTS
Beware of parts which are live! The generator
generates a high voltage up to 340 Volt
5.1.1 General
If any problem should occur, check basic conditions and
examine all external wiring, switch gear and circuit
breakers. Check if the V-belt slips. Check the V-belt
alignment (refer to figure 6). Also check if measuring
instruments give the correct value. If in doubt, measure
directly on the inverter and generator terminals with an
independent instrument. A failure code is displayed when a
failure in the system is detected. Refer to the following
pages.
5.1.2 Service address
If you cannot correct a problem with the aid of the
malfunction table, contact your Whisper Power Service
Centre or WhisperPower Netherlands for an extended
service list, s[email protected].
TEL INT + 31-512-571550.

TROUBLE SHOOTING
EN / W-BD3.5/W-BD5 BeltPower / November 2011 15
5.1.3 Display indication overview
C Continuously lit
F Slowly flashing
Display Brief description Description activation
and end of activation
Interruption
excitation Critical
Alarm
LED
GENER-
ATION
GREEN
LED
WARNING
YELLOW
LED
LOW RPM
ORANGE
LED
ALARM
RED
Interruption
output
OPERATION FAULT TAKE AWAY THE CAUSE OF THE FAULT AND RESET
AC Under
Voltage Output voltage too low Voltage lower than limit
(180 V) for a certain time
(1.8 sec) Yes Yes Yes
C
No RPM Engine stopped RPM lower than limit
(1.200 min-1) No – No
F
Over-speed Alarm engine RPM out of
limit RPM higher than limit
Yes Yes after
short
delay. Yes
C
Low RPM Engine RPM too low for
required energy RPM lower than limit No No No
C C
Short circuit Output short circuit Numbers of impulses from
PWM with CC detected Yes Yes Yes
C
Over-load Alarm overload
Maximum ( 3.5kW: 17A)
( 5kW: 23A) Yes Yes Yes
C
High-load High load related to RPM
RPM has to be increased
No No No
C C
Over
temperature Alarm high temperature
Limit (65 °C) exceeded
Fan will switch off when
the temperature descents
under the limit of 60°C.
Must be reset manually
Yes Fan on Yes
F
SERVICE FAULTS PLEASE REPORT FAULTS TO SERVICE DEPARTMENT
AC Over
Voltage Output voltage too high
Voltage higher than limit
(260 V) for a certain time
(1.8 sec)
Yes Yes Yes
C
Mag fault Short circuit in excitation Alarm caused by
hardware fault /wiring Yes Yes
Yes C
V driver low Alarm excitation voltage
too low or M121 fault
Voltage of inner circuit
less than limit: 14,4V Yes Yes
Yes C
Param Error Parameters module M121
fault Control parameters Yes Yes
Yes C
DC Over
Voltage Voltage DC Bus too high
Alarm produced by
Hardware
Yes Yes Yes C

TROUBLE SHOOTING
16 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
5.1.4 Fault finding table when the system is not working

TROUBLE SHOOTING
EN / W-BD3.5/W-BD5 BeltPower / November 2011 17
5.1.5 Fault finding table when the system stops working

TROUBLE SHOOTING
18 November 2011/ W-BD3.5/W-BD5 BeltPower / EN
5.1.6 Overview display modes

TROUBLE SHOOTING
EN / W-BD3.5/W-BD5 BeltPower / November 2011 19
5.2 SPECIAL PROCEDURES GENERATOR
5.2.1 Checking the windings
When the basic conditions are in good order and a
generator failure is suspected one should measure the
output voltage on the generator and on the cable output to
the inverter.
When the voltage between the phases of the output
terminals of the generator is wrong (should be between
200 and 360 Volt) one could also measure the resistance
of the windings for a confirmation of a winding failure.
The resistance between socket connections 1 – 2, 2 – 3
and 3 – 1 should be 783 mΩ±20 mΩ.
The resistance between socket connection 4 – 5 should
be: 3.5 kW: 2.85 Ω±0.1 Ω5 kW: 2.85 Ω±0.1 Ω.
Measure the resistance between the generator housing
and each of the cables 1 to 5. The resistance should be
more than 1MΩfor a sufficient insulation between winding
and ground.
6 SPARE PARTS LIST
ARTICLE NO DESCRIPTION
41301000 Belt Power 3.5 kW
41302000 Belt Power 5 kW
41301001 Generator 3.5 kW
41302001 Generator 5 kW
41301002 Inverter box 3,5 kW
41302002 Inverter box 5 kW
41301010 Brushes replacement kit
41301011 Bearing kit.
41301020 Shielded cable 5m
41301021 Shielded cable 8 m
41301022 Shielded cable 10 m
41301025 Cable remote control unit 5 m
41301026 Cable remote control unit 10 m
50209133 Cable remote control unit 15 m
41301030 Remote control unit
41301031 Sticker remote control unit
41301040 Set washers for alignment
41301050 Standard pulley Poly 6 V Ø60 mm
41301051 Pulley Poly 6 V Ø50 mm
41301052 Pulley Double V 12.7 mm Ø 70 mm
Other pulleys on request
Refer also to our WEBSITE: WHISPERPOWER.EU.
Fig. 8: Alternator connections

Kelvinlaan 82, 9207 JB Drachten, The Netherlands
www.whisperpower.com/ [e-mail]