WhisperPower GV4 Piccolo User manual

INSTALLATION MANUAL
High-efficiency 4kW Genverter for marine use
V1.1 May 2017
WHISPERPOWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.com
Art.no. 40200831

CONTENTS
2May 2017 / M-GV4 Piccolo for marine applications / EN
CONTENTS
1INTRODUCTION .......................................................................................................................................................................... 3
1.1 Use of this manual................................................................................................................................................................ 3
1.2 Validity of this manual.......................................................................................................................................................... 3
1.3 Installation parts................................................................................................................................................................... 3
1.4 CHP: Combined Heat and Power generation........................................................................................................................ 3
2INSTALLATION ............................................................................................................................................................................ 4
2.1 General ................................................................................................................................................................................. 4
2.2 Location................................................................................................................................................................................ 4
2.3 Protection against dirt, water, high temperature and weather conditions.......................................................................... 4
2.4 Instructions for optimal sound and vibration insulation ...................................................................................................... 4
2.5 Ventilation ............................................................................................................................................................................ 5
2.5.1 General .............................................................................................................................................................. 5
2.6 Connections.......................................................................................................................................................................... 5
2.6.1 Overview............................................................................................................................................................ 5
2.7 Fuel supply............................................................................................................................................................................ 5
2.7.1 Fuel tank ............................................................................................................................................................ 5
2.7.2 Fuel lift pump..................................................................................................................................................... 5
2.7.3 Fuel pipes........................................................................................................................................................... 7
2.7.4 Fuel filters .......................................................................................................................................................... 7
2.8 Cooling.................................................................................................................................................................................. 8
2.8.1 General .............................................................................................................................................................. 8
2.8.2 Inter-cooling ...................................................................................................................................................... 8
2.8.3 Raw water supply............................................................................................................................................... 8
2.8.4 Installation of through hull fitting...................................................................................................................... 9
2.8.5 Water strainer.................................................................................................................................................... 9
2.8.6 Siphon breaker (air vent) ................................................................................................................................... 9
2.9 Exhaust system..................................................................................................................................................................... 9
2.9.1 Standard wet exhaust system installation ....................................................................................................... 10
2.9.2 “Super silent" exhaust system ......................................................................................................................... 10
2.10 Dry exhaust system ............................................................................................................................................................ 12
2.10.1 General remarks .............................................................................................................................................. 12
3ELECTRICAL INSTALLATION (12 VOLT) ....................................................................................................................................... 14
3.1 Engine control system ........................................................................................................................................................ 14
3.2 Starter battery .................................................................................................................................................................... 14
3.3 Other recommendations and warnings.............................................................................................................................. 14
3.4 AC power system (230 Volt) ............................................................................................................................................... 14
3.5 Cable protection (fuses) ..................................................................................................................................................... 14
3.6 Grounding........................................................................................................................................................................... 15
3.7 Cable................................................................................................................................................................................... 15
3.8 Transfer switch ................................................................................................................................................................... 15
4INSTALLATION SPECIFICATIONS ................................................................................................................................................ 16
4.1 General ............................................................................................................................................................................... 16
4.2 Commissioning table .......................................................................................................................................................... 16
4.3 Technical data .................................................................................................................................................................... 16
4.4 Specification of the accessories.......................................................................................................................................... 17
4.5 Installation materials.......................................................................................................................................................... 17
5DIAGRAMS & DRAWINGS ......................................................................................................................................................... 21
5.1 Electrical diagrams.............................................................................................................................................................. 21
5.2 Mechanical drawings.......................................................................................................................................................... 23

INTRODUCTION
EN / M-GV4 Piccolo for marine applications / May 2017 3
1INTRODUCTION
1.1 USE OF THIS MANUAL
This manual serves as a guideline for the safe and effective
installation of the WhisperPower GV4 Piccolo Genverters for
marine applications.
It is obligatory that every person who is involved with the
installation of the Genverter must be completely familiar with
the contents of this manual, and that he/she carefully follows
the instructions contained herein.
To ensure reliability and durability of the equipment, it is very
important that the installation is carried out with the utmost
care and attention. To avoid problems, such as temperature
problems, noise levels, vibration, etc. the instructions set out in
this manual must be followed and all installation work must be
carried out only by qualified, authorized and trained personnel,
consistent with the locally applicable standards and taking into
consideration the safety guidelines and measures (Chapter 2 of
the user’s manual).
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.
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.
Keep this manual in a secure place!
1.2 VALIDITY OF THIS MANUAL
All of the specifications, provisions and instructions contained
in this manual apply solely to standard versions of the two and
three cylinder Genverters delivered by WhisperPower.
This manual is valid for the following models:
Part number
Description
49002005
M-GV4 Piccolo MARINE
Refer to the user’s manual for identification of the Genverter
set. For other models see our website:
www.whisperpower.com.
WARNING!
During installation and commissioning of the
Genverter, the Safety Guidelines & Measures are
applicable at all times. See chapter 2 of the user’s
manual.
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.
WARNING!
Before working (installation) on the system read
the section safety instructions in the user’s
manual
1.3 INSTALLATION PARTS
Besides the parts that are included with the delivery you need
at least the parts listed at section 4.4 to install the Genverter.
Please note that this listing may not be complete, as every
installation differs from the other. Oil is not included in the
supply. Refer to the user manual for the right specifications.
1.4 CHP: COMBINED HEAT AND POWER GENERATION
The optimum engine operating temperature is between 80° and
110° Celsius. The outgoing oil temperature is about 90° up to
110°C. The heat exchanger reduces the temperature of the
cooling liquid by 20°C to 25°C. The returning “cold” oil therefore
has a minimum temperature of at least approx. 65° Celsius.
This means that the cooling circuit can be used for heating up
water or any other medium to almost 100°C (optional). This can
be done with an additional heat exchanger. Also it could be
useful to use the hot air of the radiator for heating purposes.
WhisperPower can advise on such applications and supply
additional installation parts for CHP.

INSTALLATION
4May 2017 / M-GV4 Piccolo for marine applications / EN
2INSTALLATION
2.1 GENERAL
To ensure reliability and durability of the equipment, it is very
important that the installation is carried out with the utmost
care and attention. To avoid problems, such as temperature
problems, noise levels, vibration, etc. the instructions set out in
this manual must be followed and all installation work must be
carried out professionally.
2.2 LOCATION
When looking for a proper place for a GV4 Piccolo in a boat all
relevant aspects have to be taken into account
Accessibility
Solid foundation
Space to mount the exhaust
A route to fit the fuel lines
Since the Whisper Genverters have extremely compact
dimensions, they can be installed in tight locations. Please
consider that even almost maintenance-free machinery must
still remain accessible.
When selecting the location area in which to mount the
Genverter, make sure there is sufficient room to carry out any
maintenance work. The unit must be easily accessible on the
service side.
All models can be serviced from one side. Oil filling can be done
on the service side and on the top. (The top of the engine
(rocker cover) has to be accessible for adjustment of the valve
clearance.
Please also note that in spite of the automatic oil pressure
switch it is still essential that the oil level is checked regularly.
2.3 PROTECTION AGAINST DIRT, WATER, HIGH
TEMPERATURE AND WEATHER CONDITIONS.
The unit is designed to be mounted inside a boat. The
Genverter is not suited to mount on deck in the open air to be
subjected to bad weathers conditions and (salt) water spray
and rain or snow. The best place is a dedicated machine room.
Also inside the boat, the Genverter should be protected against
bilge water, condensation, frost and other conditions that will
affect the machinery. The air inlet of the engine room must be
protected against the ingress of water and it is recommended
to fit an air inlet strainer for protection against dirt and dust.
2.4 INSTRUCTIONS FOR OPTIMAL SOUND AND
VIBRATION INSULATION
Position the GV4 Piccolo as low as possible in the vessel. The
Genverter is secured to the base frame inside the canopy by
means of a double flexible engine mountings system. This
frame is must be solidly mounted in the vessel, not using rubber
mountings again. When it is possible to mount the unit directly
on the vessel’s frames this has advantages in preventing
vibrations by resonance.
2.4.1 Further recommendations
Whisper generating sets are standard equipped with a sound
cover canopy. This sound cover has been designed to give
effective sound insulation. For optimum sound and vibration
dampening, the following factors should be considered.
1. Most important is the structure on which the Genverter is
placed to be stiff. Directly below the base frame the
structure should be supported vertically to the trusses of
the boat. When this is not possible horizontal structures
should be made stiff by additional provisions (refer to
Figure 1).
2. In larger vessels a separate and insulated machine room
for the Genverter will help to damp the noise even further
3. Avoid mounting the generating set in close proximity to
thin walls or floors that may cause resonance.
4. Sound dampening is extremely poor if the generating set is
mounted on a light weight flimsy surface such as plywood
which will only amplify vibrations. If mounting on a thinner
surface cannot be avoided, this should be at least be
reinforced with stiffening struts or ribbing. If possible,
holes should be drilled or cut through the surface to help
reduce the resonance. Covering the surrounding walls and
floors with a heavy coating plus foam will certainly
improve the situation.
5. Never connect the base of the generating set directly to
walls or tanks (refer to Figure 1).
Figure 1: Mounting of a Whisper generating set. X = wrong, V = OK

INSTALLATION
EN / M-GV4 Piccolo for marine applications / May 2017 5
2.5 VENTILATION
2.5.1 General
The Genverter normally draws air from the engine
compartment or machine room. An engine compartment with
natural ventilation must have vent openings of adequate size
and location to enable the Genverter to operate without
overheating. To allow an ample supply of air within the
temperature limits of the generating set an opening of at least
100 cm2 is required.
A "sealed" engine compartment must have a good extraction
ventilator to maintain reasonable ambient temperatures. High
temperature of intake air reduces engine performance and
increases engine coolant temperatures. Air temperatures above
40°C reduce the engine power by 2% for each 5°C of rise.
Further the electronic inverter is rated for 40°C. At higher
temperatures the electric output will be lower. To minimise
these effects the engine room temperature must not be more
than 15ºC above the outside ambient air temperature.
Apply a combination of ventilators, blowers and air intake
ducting to meet the temperature limit. The air inlet ducts
should run to the bottom of the engine compartment to clear
fumes from the bilge and to circulate fresh air. Air outlets
should be at the top of the engine compartment to remove the
hottest air. An engine compartment blower should be used as
an extraction ventilator to remove air from the engine room.
In cases where it is impossible to meet the above mentioned
temperature limit by using engine compartment ventilation,
connections are to be made for an air inlet directly to the
Genverter enclosure.
Air inlets should be louvered, where appropriate, to protect the
engine room and to protect the generating set from water
spray.
2.6 CONNECTIONS
2.6.1 Overview
The Genverter GV4 Piccolo comes supplied with all supply and
output lines (i.e. cooling water connections, exhaust, fuel lines
etc.) already connected to the engine and inverter. The supply
lines are fed through the capsule’s front base.
The connections are marked as shown in Figure 2 (next page).
All electrical connections, cable types and sizes must comply
with the appropriate national regulations. Supplied cables are
rated for ambient temperatures up to 70°C.
If the cables are required to meet higher temperature
requirements, they must be run through conduits.
ATTENTION!
Before working (installation) on the system read
the section safety instructions.
2.7 FUEL SUPPLY
2.7.1 Fuel tank
Fuel tanks should be made of appropriate material such as
(stainless) steel or plastic. Steel tanks should not be galvanised
or painted inside. Condensation can occur in metal tanks when
temperature changes. Therefore, water accumulates at the
bottom of the tank and provisions should be made for the
drainage of this water.
The tank will need a filling connection, a return connection and
an air ventilation connection which will require protection
against water entry.
Some official regulations do not allow connection points at the
base of the fuel tank; connections are to be made at the top of
the tank with internal tubing down to a few cm above the
bottom of the tank. Using the existing fuel tank of the car-
engine the fitting should be carried out with extra care. Both a
supply line and a return line should be installed and go into the
tank from the top. Interference of the two systems (car engine
and Genverter engine) should be avoided.
2.7.2 Fuel lift pump
Apart from the machine fuel pump, the generating set is
supplied with a separate fuel lift pump; therefore the tank can
be installed at a lower level than the generating set (see
Figure 3). The maximum suction height is 1 m.
If the pump has to lift the fuel higher than one meter an
external fuel lift pump must be installed (Art. No. 50201062).
When using a second electric fuel supply pump, it is
recommended to mount a loose supplied pump close to the
tank and mount it in an angle or vertical to prevent air bubbles
to block the system. The pump makes clicking noises and
therefore could be mounted on rubber mountings. When the
clicking noises of the pump are not acceptable another
noiseless pump is available as an option (Art. No. 50202200).

INSTALLATION
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Figure 2: Connections of the GV-4 Piccolo
Figure 3: Fuel supply (fuel tank is below the Genverter)
Fuel lift pump
Fuel out
Siphon breaker
loop out
5
4
3
2
1
1
2
3
4
5
7
6
8
6
7
8
Engine control and
3-phase power output
Battery connections
Fuel in
Sea water in
Siphon breaker
loop in
Front view
Bottom view

INSTALLATION
EN / M-GV4 Piccolo for marine applications / May 2017 7
Figure 4: Fuel supply (fuel tank is above the Genverter)
Figure 5: Fuel line assembly with fuel lift pump mounted vertically or in an angle
2.7.3 Fuel pipes
When the tank is above the generating set (Figure 4),
WhisperPower recommends ending the return line on the top
of the tank.
When the return is on the top - in case of a leakage the return
line cannot overflow because of siphoning. One will only need a
fuel cock in the fuel supply line. When the tank is below the
generating set (Figure 3) we recommend ending the return line
on the bottom of the tank (A) below the inlet of the supply line.
In this way the fuel cannot drain back into the tank when the
engine is stopped; as the return line will not let air in. This
prevents starting trouble caused by air in the fuel supply line.
Both supply and return fuel pipe lines should be appropriate
material and 8 mm outer diameter tubing. The quality of the
tubing of fuel pipes could be submitted to local regulations
depending on the application of the boat.
The fuel pipes can be plumbed to the flexible hoses which are
on the generating set and have a connection to fit to 8 mm
pipe. This fuel lines fulfils CE standards and are according to ISO
7840 A2.
It is important to avoid bends in the pipes, as they could trap air
bubbles. The return pipe should never be connected to the
suction pipe. The return line should be of 8 mm diameter and
go straight back to the tank. When the return is too narrow, has
too many bends and goes back to the bottom of the fuel tank,
the back-pressure could be too high. This results in irregular
running of the engine. When the engine runs irregular, one can
check if back-pressure is the problem by disconnecting the
return line just outside the canopy and draining it in a canister.
When the engine runs smooth now, the return piping has to be
changed. It could also help to install a second (electrical 12V)
fuel lift pump in the supply line to increase the pressure.
2.7.4 Fuel filters
A fine fuel filter is installed which requires maintenance.
advises to install an extra fuel filter/ water fuel separator near
the fuel tank.
Before starting your generating set for the first time follow the
fuel system bleeding procedure in the user manual.
Fuel lift pump

INSTALLATION
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2.8 COOLING
2.8.1 General
For the cooling of an engine on a boat there are two methods
available: inter-cooling and keel cooling. Inter-cooling is based
on a raw water pump, heat exchanger and water-injected
exhaust.
Keel cooling means cooling the coolant (in case of the GV4
Piccolo this is oil) by circulating the hot coolant through a space
in the keel, or through a double walled skin of the boat,
through a box cooler welded in a steel boat, using a big tank or
any other external cooler.
Most of the time; using keel cooling, one apply a dry exhaust,
but other combinations could be supplied on request:
1) Inter-cooling with water injected a wet exhaust
2) Inter-cooling with a dry exhaust
3) Keel cooling with a dry exhaust
4) Keel cooling with a wet exhaust
2.8.2 Inter-cooling
When applying inter-cooling the Genverter should have its own
sea water inlet and should not be connected to any other
engine systems (see Figure 6). A properly installed cooling
system is critical to keep engine temperatures within an
acceptable range. Ensure that the installation complies with the
following installation instructions.
2.8.3 Raw water supply
For raw water supply the following installation materials are
required: -a skin fitting - a sea cock - a water strainer - hoses
and clamps. In order to keep the suction resistance in the line
at a minimum, the sea water intake system (i.e. sea cock, thru-
hull fitting, inlet filter, etc.) must have an inner diameter of at
least 12.5 mm diameter (1/2"). The suction hose should be kept
as short as possible. Raw water plumbing should avoid bends as
much as possible.
Restriction of raw water flow, caused by kinked hoses,
undersized pipes or connections, will reduce the engine cooling
capability. This is the main cause for overheating of an engine.
When in doubt check the coolant flow rate using a stopwatch
and by holding a pail of a known volume under the wet-exhaust
outlet. The flow rate should be 8 to 12 litres /min.
1 Water level
5 Air vent (Siphon breaker);
2 Water/exhaust separator
6 Water strainer;
3 Seacock
7 Seacock.
4 Waterlock
Figure 6: Raw water cooling system

ELECTRICAL INSTALLATION (12 VOLT)
EN / M-GV4 Piccolo for marine applications / May 2017 9
2.8.4 Installation of through hull fitting
It is good practice for yachts to use a hull inlet fitting with an
integrated strainer (water scoop). For propulsion engines in
motorboats the water scoop is often mounted against the
sailing direction to induce more water intake for cooling.
Figure 7: Installing water intake
THIS SHOULD NOT BE DONE IN THE CASE OF A
GV4 Piccolo OR ANY OTHER GENVERTER! WHEN
SAILING AT HIGHER SPEEDS, WATER WILL BE
FORCED INTO THE INLET AND YOUR ENGINE WILL
OVERFLOW!
See Figure 7. On motorboats and on sailing boats the water
scoop for a GV4 Piccolo should be fitted with the opening faced
backwards to prevent water being forced in during sailing. Use
a sealant when mounting the skin fitting.
2.8.5 Water strainer
Use an appropriate water strainer with connections of 12.5 mm
(1/2"). Install the water strainer in a well accessible position,
(refer to Figure 6, ref 6) 5 cm above the waterline.
2.8.6 Siphon breaker (air vent)
When the point of water injection is below the waterline, then -
when the engine is stopped -there is a risk that the cooling
water may enter the engine as a result of siphoning. To avoid
this happening, the GV4 Piccolo is designed to accommodate a
siphon breaker (air vent). In the standard delivery of the GV4
Piccolo connections are bypassed. Hose of 12.5 mm (1/2") inner
diameter should be used.
If the GV-4 cannot be mounted such that the bottom of the GV-
4 is placed above the waterline, an air vent must be installed.
Extend the water hose of the by-pass 60 cm above waterline
and install an air vent. Ideally, the air vent should be mounted
above the yacht keel centre line (i.e. to minimize the influence
of swaying on the water intake).
Fast motorboats will lay deeper when sailing at large speed
(non-planing) and have additional pressure on the water inlet.
This should be avoided to prevent water from entering into the
engine.
If the air vent is clogged the water hoses will not
be vented when the GV-4 has stopped and water
can be forced into the engine. this leads to
immediate engine problems and eventually
severe damage!
DAMAGE CAUSED BY THE INGRESS OF WATER IN
THE ENGINE IS NOT COVERED BY WARRANTY.
The siphon breaker that is delivered with the Whisper Power
siphon breaker installation kit does not require a connection for
a hose to drain the little water that could be spilled from the
valve. If you use another kind of siphon breaker that has a hose
connection, make sure that the drain should go downwards
down directly and that it may not end under water. Water must
flow out freely and air has to flow in freely as well (refer to
Figure 8).
Figure 8: Wrong siphon breaker hose routing (non-Whisper
Power siphon breaker)
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required (Figure 8).
2.9 EXHAUST SYSTEM
Inter-cooling is almost always combined with a wet exhaust
system: Water is injected in the exhaust system of the
Genverter. In this way the cooling water that has passed the
heat exchanger is mixed with the exhaust gases. Temperature
and volume of the gases are thereby reduced considerably, so
that a rubber exhaust hose can be used and the level of noise is
reduced as well.
However a dry exhaust is possible dumping the water over
board separately.
Keel cooling is almost always combined with a dry exhaust.
SAILING DIRECTION
SAILING DIRECTION
FLOW DIRECTION
FLOW DIRECTION

INSTALLATION
10 May 2017 / M-GV4 Piccolo for marine applications / EN
1 Exhaust water lock;
4 Goose neck;
Figure 9: Standard exhaust system
2 Exhaust outlet muffler;
5 Through-hull exhaust outlet Ø 40 mm;
3 Exhaust line Ø 40 mm;
6 Water level.
2.9.1 Standard wet exhaust system installation
The Genverter wet exhaust system must remain completely
independent and separate from the exhaust system of any
other engine on board. A water lock prevents the Genverter
from being flooded by cooling water and should be installed as
close to the Genverter as possible. The lock must be large
enough to hold the entire water volume held in the hose from
the top of the goose neck to the water lock. The water lock
must be installed at the lowest point of the exhaust system
(refer to Figure 9, ref. 1). The exhaust hose must have an inner
diameter of 40 mm no less, no more-. The exhaust system must
be installed so that the back pressure inside the exhaust does
not exceed 0,8 psi 60 cm. water pressure (refer to the user’s
manual) and total length up to the outlet or water separator
does not exceed 2,5 m. The exhaust hose descends from the
capsule to the water lock. Then the hose rises maximum lift 120
cm via the "goose neck" to the through-hull exhaust outlet,
situated minimum 50 mm above the water line (refer to
Figure 6, ref. 5). The "goose neck" must be vertical and situated
preferable along the ship’s keel centre line. It is recommended
to install an extra muffler (see Figure 9, ref. 2) close to the
through-hull fitting.
Because of the small gas flow of the small engine
it is very important to keep strictly to the
instructions above. some mufflers and water locks
cause too high back pressure. It is recommended
to use a WhisperPower installation kits or check
the back pressure (refer to the user’s manual).
Too high back pressure causes the system to fill
up with water affecting the outlet valve and valve
seat.
2.9.2 “Super silent" exhaust system
See Figure 10. In order to reduce the noise level of the GV4
Piccolo to a minimum, an option to reduce the exhaust noise
further (especially exhaust water splashing) is an exhaust/water
separator. The exhaust/water separator allows the cooling
water to be ejected through a line separate from the exhaust
fumes and also functions as a goose neck to prevent water from
flooding the engine. The exhaust/water separator is mounted
more than 60 cm above the water level.
See Figure 11. If the through-hull exhaust outlet has to be
mounted far from the GV4 Piccolo, an exhaust/water separator
must definitely be installed. (Total length of the exhaust piping
from Genverter to top of goose neck (water separator) is more
than 2,50 m.) The sea water from the separator must run down
along the shortest possible path to the through-hull outlet.