634269

WhisperGen PPS16 DC Handleiding

1
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Personal Power Station
User’s Manual
PPS16 Marine and Land Version
Kerosene or Diesel Fuel
12 or 24 Volt Battery Bank Capacity
WHISPER TECH LIMITED
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2
FUEL OFF
ON
Personal Power Station
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
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Whisper Tech Ltd. reserves the right to revise or change the specifications of its products. This
publication describes the state of this product at the time of its publication and may not reflect the
product at all times in the future.
Patents granted and pending worldwide.
Whisper Tech , WhisperGen,
Personal Power Station, and WhisperGen Personal Power Station
are registered trademarks of Whisper Tech Limited.
Copyright © 2002 Whisper Tech Limited.
All rights reserved.
Printed in New Zealand.
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Title User Manual PPS16 DC
Part Number DO-40015-D
C/N Number 464
Application This manual applies to WhisperGen model numbers
PPS16 12 MD,
PPS16 24 MD and
PPS16 24 LK
in the following installations:
• Marine & Land applications.
• Diesel & Kerosene fueled burners.
• 12V and 24V DC battery systems.
Read this manual from cover to cover before attempting to use the WhisperGen. This manual
contains important operating, care and maintenance, trouble shooting, warnings and safety
procedures. Follow them! If you don’t understand a point in this manual, don’t guess. Get help!
Contact your authorised WhisperGen representative.
Along with the warnings, instructions and procedures in this manual, the user should also observe
such other common sense procedures generally applicable to equipment of this type. If the user
does not follow these and other such common sense warnings, instructions and procedures, the
WhisperGen may not perform as expected. More seriously, it may cause property damage,
personal injury or other losses. The serious risks associated with the WhisperGen are fire,
explosion, carbon monoxide and electric shock. Fortunately, these risks are exceedingly remote,
provided you know what you are doing and exercise all due care.
Whisper Tech accepts no liability for direct, indirect, incidental, special, or consequential damages
resulting from the user’s failure (or the failure of the installer or service technician) to follow the
warnings, instructions and procedures in this manual or such other common sense procedures
generally applicable to equipment of this type. The foregoing limitation extends to damages to
person or property caused by the WhisperGen, or damages resulting from the inability to use the
WhisperGen, including loss of profits, loss of products, loss of power supply, the cost of arranging
an alternative power supply and loss of time, whether incurred by the user, its employees, the
installer, a service technician or a third party.
Whisper Tech used all due care in preparing this manual. However, Whisper Tech accepts no
liability for errors or omissions.
Whisper Tech reserves the right to change the specifications of its products, or the information in
this manual, without necessarily giving its users notice thereof.
The WhisperGen should be installed, commissioned and serviced only by persons approved by
an authorised WhisperGen representative to provide such services. Do not attempt to install,
commission or service the WhisperGen, yourself, unless you have been so approved. Whisper
Tech accepts no liability for personal injury or property damage resulting from faulty installation,
commissioning and servicing.
For each installation, operating conditions will vary, sometimes greatly. Such variations may affect
the WhisperGen’s performance. Whisper Tech has no control over the installation’s unique
operating environment. Hence, Whisper Tech makes no representations or warranties concerning
the performance of the WhisperGen under the actual operating conditions prevailing at the
installation. All operating parameters should be validated for your application by a technical expert
of your choosing.
Whisper Tech has made every effort to explain operating, care and maintenance, trouble
shooting, warnings and safety procedures as clearly and completely as possible. Nonetheless, it
is not possible to anticipate, nor address, every conceivable problem that may arise. This problem
is compounded by the diversity of operating environments in which the WhisperGen is used.
Therefore, Whisper Tech is not able to guarantee that this manual will address every issue or
problem that might arise. This manual is intended to provide general guidance. For specific
guidance and technical support, contact your authorised WhisperGen representative.
Information in this manual shall not be deemed a warranty, representation or guarantee. For
warranty provisions applicable to your WhisperGen, please refer to the warranty provided by the
supplier of your WhisperGen.
Unless otherwise noted, a reference to brand names, product names or trademarks constitute the
intellectual property of the owner thereof. Subject to your right to use the WhisperGen, Whisper
Tech does not convey any right, title or interest in its intellectual property, including, without
limitation, its patents, copyrights and know-how.
This manual is for the your personal use only. No part of it may be reproduced or transmitted in
any form or by any means without the express written permission of Whisper Tech.
Use of the WhisperGen shall constitute your acceptance of the conditions above.
(Disclaimer Version 1.2 02 02)
Table of Contents
INTRODUCTION
The WhisperGen .........................................................................................................................1,2
Introduction...............................................................................................................................1
What it does .............................................................................................................................1
How it works.............................................................................................................................2
Typical Marine Application ..........................................................................................................3,5
Typical Land Appliction ...............................................................................................................4,5
Technical Specifications..............................................................................................................6,7
Summary of Parts........................................................................................................................8,9
Control Panel Parts ......................................................................................................................10
Safety Precautions ..................................................................................................................11-15
OPERATION
Introduction...................................................................................................................................16
Installing the WhisperGen ............................................................................................................16
Quick Reference - Operating Options ..........................................................................................16
Information Structure....................................................................................................................17
Starting the WhisperGen.........................................................................................................18,19
Stopping the WhisperGen .......................................................................................................20-24
Manual Stopping ....................................................................................................................20
Emergency Stopping..............................................................................................................21
Setting the Maximum Run Time........................................................................................22-24
Remote Controlling..................................................................................................................25,26
Managing the Battery Bank.....................................................................................................27-29
Stages of Charging.................................................................................................................27
Auto-Charging the Battery Bank............................................................................................. 28
Bulk-charging the Battery Bank..............................................................................................29
Managing Heat Generation .....................................................................................................30,31
Setting the Coolant Temperature ...........................................................................................30
Turning On Heat Management...............................................................................................31
Clearing Faults and Warnings.................................................................................................32-34
Adjusting the LCD ...................................................................................................................35,36
Adjusting the Contrast............................................................................................................35
Adjusting the Backlight...........................................................................................................36
Displaying System Information................................................................................................37-44
Default Display .......................................................................................................................37
User Menu..............................................................................................................................38
Fault/Warning Menu...............................................................................................................38
Extra info Menu.................................................................................................................39,40
Installation Menu ....................................................................................................................40
Displaying Information.......................................................................................................41,42
Editing Parameter Settings................................................................................................43,44
MAINTENANCE
Introduction .................................................................................................................................. 45
Maintenance Schedule............................................................................................................45,46
Removing the Enclosure Lid ........................................................................................................47
General Checking ........................................................................................................................ 48
Checking the Fuel ........................................................................................................................ 49
Bleeding the Fuel Line ............................................................................................................50-52
Cleaning the Fuel Pump Filter.................................................................................................53-54
Checking the Coolant................................................................................................................... 55
Bleeding the Coolant Circuit....................................................................................................56-59
Checking Battery Bank Connections.......................................................................................60,61
Replacing the Glow Plug.........................................................................................................62,63
Replacing Fuses .....................................................................................................................64-66
Replacing the FID ...................................................................................................................67-69
Replacing the Oxygen Sensor ................................................................................................70,71
Replacing the Evaporator........................................................................................................72-74
Flushing the Exhaust Heat Exchanger....................................................................................75-77
TROUBLE SHOOTING
Correcting Faults.....................................................................................................................78-82
Correcting Warnings ...............................................................................................................82,83
Resetting the WhisperGen...................................................................................................... 84,85
SERVICE DETAILS................................................................................................................86-89
EC CONFORMITY.................................................................................................................. 90,91
INDEX .....................................................................................................................................92,93
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1
The WhisperGen
Introduction
Congratulations on purchasing a WhisperGen PPS16.
This manual is designed to allow you to quickly learn how to safely operate your WhisperGen.
Please keep this manual for future reference and read it before operating or maintaining your
WhisperGen.
For information regarding the standard kit items supplied with each WhisperGen, and if you have
any questions or suggestions feel free to contact your authorised WhisperGen agent.
In some countries, it is a requirement that this manual be permanently placed alongside the
WhisperGen and maintained in a readable condition. Check with your local authority regarding
this requirement.
What it Does
The WhisperGen PPS16 is a Personal Power Station that generates heat and electrical energy
simultaneously.
The WhisperGen is capable of charging and managing a lead-acid battery bank to provide a DC
electrical power supply.
It also provides heat energy in the form of hot coolant for space heating and domestic hot water
generation.
Note: Not all elements of the actual system are shown in this schematic.
In this manual, warnings against hazards are marked with the symbol
shown on the left. Heed all warnings at all times.
!
ELECTRICAL
APPLIANCES
·
Refrigerator
·
Washing Machine
·
Microwave
·
Video Recorder
·
Television
·
etc
.
INVERTER
(Converts DC
to AC)
+
+
–
BATTERY
BANK
DC APPLIANCES
(12 or 24 Volt DC)
Electricity
(DC)
WHISPERGEN
Coolant
HOT
WATER
CYLINDER
HEATER
Personal Power Station
ON
OFFFUEL
WTL0001
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2
How It Works
The WhisperGen PPS16 is based on a four-cylinder Stirling-cycle (external combustion) engine
that repeatedly heats and cools a mass of pressurised nitrogen gas. Each time the gas is heated
and cooled, the changing gas pressure causes the pistons to move up and down. This
mechanical motion, via a special mechanism called the “wobble yoke”, rotates an alternator to
generate DC electricity which can be used to charge a lead-acid battery bank.
The nitrogen gas is heated by a continuous-combustion burner, and cooled by coolant circulating
through engine cavities. Heat transferred to the coolant can be used to heat domestic water
cylinders and for space heating.
The burner consumes air and fuel. The flow rate of air and fuel into the burner is optimised by a
microcomputer. This maximises combustion efficiency and minimises exhaust emissions.
The microcomputer automatically controls all WhisperGen functions and displays real-time
information about the system on a control panel from which the user can also alter operating
options.
BATTERY
BANK
AND/OR
ELECTRICAL
DEVICES
HOT WATER
AND/OR
SPACE
HEATING
CONTROL
SYSTEM
BURNER
(Continuous combustion)
STIRLING ENGINE
(Closed thermodynamic cycle)
EXHAUST
HEAT EXCHANGER
ALTERNATOR,
RECTIFIER,
LOAD DUMP (CLAMP)
Oxidant
Heat energy
Heat energy
(as hot exhaust
gases)
Data
Control
Mechanical energy
Recovered heat energy
(as hot coolant)
Electrical energy
Heat energy
(as hot
coolant)
Unused
heat energy
(as cool
exhaust gases)
FUEL
AIR
Control
Data
Data
Data
Data
Control
WTL0002
Chemical energy
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3
Typical Marine Application
Electrical
Appliances
DC
Appliances
Refrigerator
Washing Machine
Microwave Oven
Video Recorder
Television
Music Centre
Etc.
(12 or 24 Volt DC)
1
3
4
5
6
7
2
8
9
20
17
18
19
21
16
11
15
22
13
12
23
24
14
10
WTL0003
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
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4
Typical Land Appliction
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
Electrical
Appliances
DC
Appliances
Refrigerator
Washing Machine
Microwave Oven
Video Recorder
Television
Music Centre
Etc.
(12 or 24 Volt DC)
1
3
4
5
6
7
2
20
17
18
19
21
16
11
15
13
12
23
24
25
14
10
WTL0004
Foul water drain
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5
No Description
1 WhisperGen PPS16.
2 Engine Block.
3 Exhaust heat exchanger.
4 Coolant header tank.
5 Coolant pump.
6 Hot water cylinder (optional).
7 Space heater (optional).
8 Marine heat exchanger.
9 Seawater pump.
10 Electronics enclosure.
11 Current shunt.
12 DC appliances (12/24 Volt).
13 Inverter (DC to 230/110 Volt AC).
14 Electrical appliances (230/110 Volt AC).
15 Battery bank (12/24 Volt).
16 Circuit breaker.
17 Fuel tank.
18 Fuel filter.
19 Fuel pump.
20 Exhaust gases vented into atmosphere.
21 Condensate drain.
22 Seawater.
23 Control panel.
24 Remote start/stop switch (optional).
25 External heat dump radiator (optional).
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Technical Specifications
Specifications subject to change without notice
Feature Specification Remark
Prime mover 4-cylinder Stirling-cycle engine
pressurised to 28 bar with nitrogen.
Closed thermodynamic cycle.
Power output Co-generation of heat and electricity.
Heat 5kW useable heat. Heat output depends on
operating conditions.
Electrical 750W electrical. Gross output depends on
operating conditions.
Duty cycle 1 to 24 hours per day.
Fuel **
Type Kerosene: BS2869: 2000 Class C1 or
C2
Minimum flash point, closed,
43°C for C1, 38° C for C2.
Type Diesel: EN590; BS2869: 2000 Class
A2, D.
Minimum flash point, closed,
56°C.
Consumption Less than 1 litre per hour. At nominal power output.
Control
Manual Manual start/stop from control panel.
External Optional remote starting via external
switch.
Timer, thermostat, or on/off
switch may be used.
Auto-charge Optional automatic battery bank
charging.
Starts and stops at preset
discharge levels.
Heat management Optional automatic heat generation to
maintain coolant temperature.
Coolant temperature is user-
selectable.
External heater Optional control of an external heater to
boost and maintain coolant
temperature.
Coolant temperature is user-
selectable.
Electrical **
Nominal voltage 12V or 24V DC.
Battery bank
capacity
12V: 200Ah minimum recommended.
24V: 100Ah minimum recommended.
Battery bank not included in
standard kit.
Battery bank
charging
3-stage charging on each run: bulk,
absorption, and float.
Battery bank voltage, current,
and Amp-hours monitored and
displayed on control panel.
** Machine type is set at the factory
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7
Feature Specification Remark
Cooling system
Cooling method Primary Cooling:
Automotive type glycol-based
corrosion-inhibited antifreeze.
Removes heat from engine.
Secondary Cooling:
Water-cooling (marine applications).
External Radiator (land applications).
Heat is transferred to hot water
cylinder(s) and space heater(s).
Heat exchangers Internal exhaust and marine heat
exchangers.
Requires external coolant pump
and seawater pump.
Exhaust temperature 80°C nominal, 95°C maximum. Cooling system extracts heat
from exhaust.
Connections All connections provided on the
rear panel of the enclosure.
Fuel Rp 1/8 (ISO 7-1). BSPP 1/8
Heat exchangers Rp 3/4 (ISO 7-1). BSPP 3/4
Exhaust Rp 1 1/4 (ISO 7-1). Exhaust must be vented outside
occupied areas.
Exhaust flushing G 3/4 (ISO 228-1). Face sealing fitting required.
Condensate draining 12.7mm O.D. plain tube.
Battery bank 35mm² screw terminals.
External switch 0.5 to 2.5mm² screw terminals.
PC RJ 45. Via RS485-to-RS232 converter.
Physical
Dimensions 450mm (W) x 500mm (D) x 650mm (H).
Dry weight 90kg.
Enviromental
Temperature/humidity -10°C to 40°C. 99% RH, non-
condensing.
With suitable fuel and coolants.
Compliance
Machinery directive 98/37/EC.
Noise ISO 8528-10. 50dBA at 7m.
EMC directive 89/336/EC, 92/31/EC and 98/13/EC.
EMC EN50081-1.
EN50082-1.
Radiated and conducted
emissions.
RF field, ESD, and fast transient
immunity.
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8
Summary of Parts
2
FUEL OFF
ON
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0005
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Personal Power Station
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9
10
11
12
13
1
2
3
4
5
6
7
8
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No Name Function
1 Enclosure The fibreglass-reinforced cover that
protects the internal parts of the
WhisperGen.
2 Electronics Enclosure The electronics, including a
microcomputer, that controls all
WhisperGen functions and regulates
power supply to and from the
WhisperGen and battery bank.
3 Fuel Valve A manually operated valve that isolates
the WhisperGen from its fuel supply,
stopping combustion and shutting
down the engine.
4 Control Panel The remote panel for viewing
information about the WhisperGen
system and controlling operating
parameters.
5 Fuel Line The tube through which fuel is supplied
to the burner.
6 Marine Heat Exchanger
(Marine version only)
A device that transfers excess heat
energy from the coolant to seawater.
7 Earthing Strap The earthing cable for the glow plug.
8 Air Blower The fan that supplies air to the burner.
9 Oxygen Sensor A sensor that feeds back to the
microcomputer the air/fuel ratio.
10 FID A flame-ionisation detector that detects
the presence of flames in the burner.
11 Glow Plug A device to preheat the burner and
ignite incoming fuel.
12 Exhaust Heat Exchanger A device that extracts heat energy from
the exhaust gases.
13 Burner A continuous-combustion device that
supplies heat to the engine.
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Control Panel Parts
No Name Function
1 START Key The key that:
(a) Starts up the WhisperGen;
(b) Begins battery bank bulk-charging; and
(c) Clears faults.
2 SELECT Keys The arrow keys that provide access to system menus for;
(a) Information display; and
(b) Editing system parameters.
3 STOP Key The key that shuts down the WhisperGen.
4 Indicators The lights that indicate the status of the WhisperGen system.
STANDBY: the WhisperGen is ready to start.
STARTING: the WhisperGen is starting.
RUNNING: the WhisperGen is operating.
STOPPING: the WhisperGen is stopping.
FAULT: a fault or warning is present.
AUTOCHARGE: the battery bank auto-charging function is
turned on.
EXT CONTROL: external control of the WhisperGen is
enabled.
HEAT MANAGE: the heat management function is turned on.
5 LCD Panel A liquid-crystal display that shows system information such as
charging current, battery bank voltage, power output, etc.
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
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5
4
3
21
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Safety Precautions
Please read and understand this section ENTIRELY before operating or
maintaining the WhisperGen. Not heeding the warnings or
recommendations could damage the WhisperGen, cause personal injury,
and/or void the warranty.
WTL0000
U
ser's
M
anual
WTL0008
In some countries, this manual must be permanently placed
alongside the WhisperGen and maintained in a readable condition.
Consult your local authority for information.
FUEL OFF
ON
WTL0015
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Personal Power Station
The WhisperGen is a pressurised device and must be installed and
serviced by an authorised WhisperGen service agent. Incorrect
installation or servicing can damage the WhisperGen and property,
cause personal injury, and/or void the warranty.
WTL0000
Always heed warning signs on the WhisperGen. The engine contains
high-pressure nitrogen and some internal surfaces are hot.
FUEL OFF
ON
Critical Applications
Other
Supply
WTL0016
R
Personal Power Station
Never use the WhisperGen as the sole source of electrical power
for critical applications.
FUEL OFF
ON
WTL0017
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Personal Power Station
The WhisperGen should be pressurised by an authorised service
agent only. Do not do it yourself and do not adjust the pressure-
relief valve.
FUEL OFF
ON
WTL0021
R
Personal Power Station
Exhaust gases from the WhisperGen should at all times be
vented outside enclosed areas. Exhaust piping in enclosed
areas must be properly sealed.
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12
WTL0024
Never remove the burner earthing strap as this will cause the fuel
line to act as the earthing path for the glow plug. The fuel could
heat up, causing a malfunction or a fire.
WTL0054
Do not use fuels other than the specified class of fuel as this
may damage the WhisperGen and/or cause a fire.
WTL0055
Air bubbles present in the fuel line can cause the WhisperGen to
malfunction – bleed the fuel line after filling a completely empty
fuel tank.
WTL0056
The cooling system is vital to the performance of the WhisperGen.
If there are leakages in the cooling circuit, or the water is not
flowing inform an authorised WhisperGen agent immediately.
WTL0057
Use only the recommended coolant mixture. Using an incorrect
type of coolant fluid can cause serious corrosion in the
WhisperGen.
WTL0058
Ensure that fuel and coolant used on the WhisperGen are clean
and free of particulate contaminants. Foreign particles can
obstruct fuel/coolant passages, resulting in a malfunction or
damage to the WhisperGen.
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14
FUEL OFF
ON
R
Personal Power Station
WTL0063
H
O
2
2
Do not operate the WhisperGen in a potentially
explosive environment.
FUEL OFF
ON
R
Personal Power Station
WTL0064
Do not store rags or other items inside or beside the
WhisperGen as the air circulation through the WhisperGen
may be disrupted.
FUEL OFF
ON
R
Personal Power Station
WTL0065
Do not drill holes in the enclosure. Air circulation
through the WhisperGen may be disrupted.
WTL0066
Do not modify the piping for the fuel, exhaust, and
cooling systems of the WhisperGen without first
consulting an authorised WhisperGen agent.
FUEL OFF
ON
R
Personal Power Station
WTL0067
Isolate the WhisperGen from the battery bank before
making or breaking other connections on the battery
bank.
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13
FUEL OFF
ON
R
Personal Power Station
2
WTL0010
During normal operation of the WhisperGen, the
enclosure lid and electronics enclosure lid must be
fitted.
FUEL OFF
ON
R
Personal Power Station
WTL0059
Bake Time____
123
456
789
0
OPEN START
Do not sit anything on the WhisperGen or press down hard on
the top.
FUEL OFF
ON
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Personal Power Station
WTL0060
Do not expose the WhisperGen to large physical impacts.
FUEL OFF
ON
R
Personal Power Station
WTL0061
Do not expose the WhisperGen to excessive vibration.
FUEL OFF
ON
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Personal Power Station
WTL0062
Do not expose the WhisperGen to extreme temperatures.
The ambient temperature should not exceed 40°C or fall
below -10°C.
FUEL OFF
ON
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Personal Power Station
WTL0009
Do not install, operate, or store the WhisperGen in a wet
or poorly ventilated place.
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15
WTL0069
1. Check x
2. Check y
3. Clean p
4. Clean q
Ensure that maintenance procedures and schedules as
recommended in this manual are adhered to at all times.
WTL0068
Perform maintenance procedures mentioned in this
manual only. If in doubt, call your authorised
WhisperGen service agent.
2
FUEL OFF
ON
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Personal Power Station
WTL0007
Before the WhisperGen is transported by
air or disposed, fluids in it must be
drained and the engine must be
depressurised. Consult your authorised
WhisperGen service agent for advice.
FUEL OFF
ON
R
Personal Power Station
WTL0070
In some countries, it is a requirement that a maintained fire
extinguisher be permanently located alongside an
installed WhisperGen. Consult your local authority for
information.
FUEL OFF
ON
R
Personal Power Station
WTL0037
In case of fire, use a carbon dioxide or dry
powder extinguisher – do not use water.
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Operation
Introduction
This section outlines the procedure for operating your WhisperGen. It will show you how to:
• Start and stop the WhisperGen;
• Charge the battery bank;
• Manage heat generation;
• Clear faults and warnings;
• Adjust the contrast of the LCD; and
• Display and edit system parameters of the WhisperGen.
Installing the WhisperGen
To install the WhisperGen, contact your authorised WhisperGen service agent. The contact
details for your authorised WhisperGen service agent appear at the back of this manual.
Quick Reference - Operating Options
Depending on the options selected, the WhisperGen may stop running before or after the battery
bank is charged, as shown in the table below.
In all cases, the WhisperGen can be stopped at any time by pressing STOP on the control panel.
* In this mode, the WhisperGen will run for at least one hour.
WhisperGen
starting method
Heat Manage ON Heat Manage OFF
Max Run Hours
< 25
Max Run Hours
= 25
Max Run Hours
< 25
Max Run Hours
= 25
Manual start
Stops when Max
Run Hours value
is reached, even if
the battery bank
is not yet fully
charged.
Continues
running until
stopped by the
user.
Stops when the
battery bank is
charged or when
Max Run Hours
value is reached,
which ever comes
first.
Continues
running until the
battery bank is
charged, then
stops.
Remote switch
start with Ext Cont
Mode set to 1
Remote switch
start with Ext Cont
Mode set to 2*
Continues
running until
stopped by the
user or remote
switch.
Auto-charge start Stops when the battery bank is charged, regardless of Max Run Hours and
Heat Manage settings.
WTL0000
You should read and understand all safety precautions before
operating your WhisperGen.
The WhisperGen must be installed by an authorised WhisperGen
service agent. If you install the WhisperGen yourself, the warranty
will be void. Incorrect installation may damage the WhisperGen and
property, and/or cause personal injury.
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17
Information Structure
The information displayed on the control panel is structured as shown below. For an explanation
on how to navigate within this information structure, individual parameter meanings and edit
settings refer the section entitled Displaying System Information.
Alt Current
Warning Code
Heat Manage
Fault / Warning Extra InfoUser
Menu
Main
Menu
Installation
Menu
Default
Display
Menu Menu
Temp Setpoint
Auto-charge
Ext. Control
Ext. Control Mode
Max Run Hours
Edit to clear
Current Warning
Last Warning
2nd Last Warning
Current Fault
Last Fault
2nd Last Fault
Start Code
Stop Code
User Menu
Battery Volts
Battery Amps
Batt Amp-hrs
Battery Watts
Gross Watts
Runtime (Min)
Hour Meter
# Of Starts
Warning Code
Extra Info Menu
Installation Menu
Fault/Warning Menu
Coolant 1 Bleed
Fuel Bleed
Air Bleed
Heat Exchanger
Nozzle Bleed
Coolant 2 Bleed
Enable Starts
3 times
Air %
Bus Voltage
Coolant Temp
Clamp Current
Clamp Voltage
Exhaust Temp
FID Current uA
Fuel Cut Off
Fuel Metering
Fuel Frequency
Glow Plug
Isolate Relay
Power Relay
Pri Cool. Flow
O2 Value
O2 Ave Error
Cycle Time
3 times
Software Ver
WTL0014
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18
Starting the WhisperGen
To manually start the WhisperGen:
1. Check that the STANDBY indicator on the control panel is lit. If the fault indicator is constantly
lit, you will need to clear the fault – see section entitled Clearing Faults and Warnings. If
nothing is displayed on the control panel, check that the WhisperGen is connected to the
battery bank and that the 3A fuse (F2 position as marked on PCB) is not blown.
2. Turn on the fuel valve.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
FUEL OFF
ON
WTL0011
OFF
ON
FUEL
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Personal Power Station
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19
3. Hold down START on the control panel until all indicators flash and a beep is heard. The
STARTING indicator will light up and “Manual start” will be displayed on the control panel. As
an anti-tamper feature, short presses of the START key are ignored.
In the starting mode, as indicated by a lit STARTING indicator, the WhisperGen goes through a
starting-up sequence over a few minutes during which the engine is heated to a working
temperature. The WhisperGen is operating normally when the RUNNING indicator lights up and
the control panel displays “Bulk Charge”. This may take up to 10 minutes. If a fault occurs, the
WhisperGen may automatically attempt to restart. By default, the WhisperGen will attempt to
restart once. If you wish to change this setting, contact your authorised WhisperGen agent.
Every time the WhisperGen is operated, the battery bank is charged. Once the battery bank is
fully charged**, the WhisperGen automatically stops and returns to the standby mode (as
indicated by a lit STANDBY indicator) if the default settings are used. (i.e. Auto charge mode)
If the WhisperGen is in Heat Manage mode, the WhisperGen will continue to run for as long as
there is a heat demand.
If you press START while the WhisperGen is in the process of stopping, it will ignore the key
press and continue stopping. The WhisperGen must be in the standby mode before it can be
started. The WhisperGen must also be allowed to cool down before it can be restarted.
The WhisperGen can also be started by remote switch, refer to section entitled Remote
Controlling for more details.
** If the WhisperGen is started manually or from a remote switch, and the Max Run Hours setting
is less than 25, the WhisperGen will automatically stop when the Max Run Hours set value is
reached, even if the battery bank is not yet fully charged.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Manual start
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20
Stopping the WhisperGen
Manual Stopping
The default setting of the Heat Manage option is OFF. Unless it is turned ON, the WhisperGen
automatically stops once the battery bank is fully charged - you do not need to manually stop the
unit.
Should you wish to manually stop the WhisperGen refer to the following:
1. Hold down STOP on the control on the control panel until a beep is heard. The STOPPING
indicator will light up and “Running down” will be displayed on the control panel. As an anti-
tamper feature, short presses of the STOP key are ignored.
In the stopping mode, as indicated by a lit STOPPING indicator, the WhisperGen goes through a
shutdown sequence lasting two to five minutes during which the engine is cooled down.
When the WhisperGen has fully stopped, the STANDBY indicator lights up and the control panel
displays “WhisperGen”. The WhisperGen must be in the standby mode before it can be started
again.
If a remote switch has been installed to control the WhisperGen, you can also stop the
WhisperGen with the remote switch, refer to section entitled Remote Controlling for more details.
If you stop the WhisperGen manually or from a remote switch when it is auto-charging the battery
bank, the WhisperGen will immediately start again if the battery bank charge level is still below
the set level. To prevent the WhisperGen from restarting, turn the Auto-charge option OFF, refer
to section entitled Managing the Battery Bank - Auto charging.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Running down
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21
Emergency Stopping
To stop the WhisperGen in an emergency:
1. Turn off the fuel valve in front of the WhisperGen.
The flame in the WhisperGen burner will be extinguished within a few seconds. The fuel cut-off
will be registered as a fault and the WhisperGen will stop. The fault will need to be cleared (see
section entitled Clearing Faults and Warnings) before the WhisperGen can be started again.
The WhisperGen will attemp to re-start (if auto restart is enabled). If the fuel valve remains off, the
attempt will fail. It is recommended that once the fuel valve has been turned off and the stop
button on the control panel activated, this will cancel all auto-restarts.
FUEL OFF
ON
WTL0012
OFF
ON
FUEL
R
Personal Power Station
Note: The WhisperGen must complete a cool down sequence,
there is no way to immediately stop the engine.
Warning: In case of fire, use a carbon dioxide or dry powder
extinguisher - do not use water.
Note: To cancel auto re-start push the stop button on the control
panel.
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22
Setting the Maximum Run Time
If the WhisperGen is started manually or from a remote switch, you can limit the operating
duration of the WhisperGen by setting a maximum operating time.
To set the maximum operating time of the WhisperGen:
1. Access the default display on the control panel by pressing
< repeatedly. See section entitled
Displaying System Information - Displaying Information.
2. Press
> to display the first item on the main menu, the User Menu
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
User Menu
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23
3. Press > to display the first item on the User Menu
4. Press
∨ to scroll down to Max Run Hours.
5. Press
> to begin editing the maximum operating time of the WhisperGen.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Heat Manage
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Max Run Hours
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24
6. Press ∧ or ∨ to select the maximum number of operating hours for the WhisperGen. If 25
(hours) is selected, the WhisperGen will run continuously until the battery bank is fully
charged.
7. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
If the Max Run Hours setting is less than 25, the WhisperGen will automatically stop when the
Max Run Hours set value is reached, even if the battery bank is not yet fully charged. If the Max
Run Hours setting is left at its default value of 25, no maximum operating time condition is
imposed: the WhisperGen will run continuously until the battery bank is fully charged.
Note that the Max Run Hours setting applies only if the WhisperGen is started manually or from a
remote switch. It does not apply if the WhisperGen automatically starts by itself as a result of the
auto-charge or heat manage function. For more information on battery bank auto-charging, see
section Managing the Battery Bank.
For a summary on operating options, see section Quick Reference - Operating Options.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Max Run Hours 21
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25
Remote Controlling
You can start and/or stop the WhisperGen using a remote on/off switch, timer, or thermostat, if
one of these is fitted.
To set the remote switch to start/stop the WhisperGen:
1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in
the section entitled Setting the maximum Run Time.
2. Press
∨ to scroll down to Ext. Control.
3. Press
> to begin editing the external control setting.
4. Press
∧ to select ON. The EXT CONTROL indicator lights up.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Ext. Control
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Ext. Control ON
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26
5. Press < to quit editing Ext. Control.
6. Press
∨ to scroll down to Ext Cont Mode.
7. Press
> to begin editing the external control mode setting.
8. Press
∧ or ∨ to select an option: 1, 2 or 3. These options are described in the table below.
9. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
The effect of starting or stopping the WhisperGen using a remote switch is similar to pressing
START or STOP on the control panel, refer to section entitled Starting the WhisperGen and
Stopping the WhisperGen.
For a summary on operating options, refer to the Quick Reference - Operating Options.
Setting Control Options Control Logic
1 Starting only The WhisperGen will start when the remote
switch is closed and will continue running even if
the remote switch is then opened.
2 Starting and stopping The WhisperGen will start when the remote
switch is closed and stop when it is opened.
Once started, the WhisperGen will operate for at
least an hour.
3 Stopping only If the WhisperGen is started while the remote
switch is closed, the WhisperGen will stop when
the remote switch is opened.
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27
Managing the Battery Bank
Stages of Charging
Every time the WhisperGen is operated, it charges the battery bank. There are three stages in a
typical charging cycle as shown below:
The absorption and float charging voltages, the current level at which absorption-charging
ceases, and other battery-charging settings, are set during the installation of the WhisperGen.
These settings are set according to the needs of your particular application. If you wish to change
these settings, contact your authorised WhisperGen agent.
Bulk-charging
The battery bank is
charged at the
maximum rate. The
voltage typically rises
2 or 3 Volts while the
current is maintained
at a fixed level.
Bulk-charging Absorption-charging Float-charging
Time
Time
Voltage across Battery
Bank Terminals
Current Supplied
to Battery Bank
Absorption-charging
The battery bank is
about 80% charged at
the beginning and the
voltage is maintained
at a fixed level to fully
charge it. The current
decreases gradually.
Float-charging
The charged state
of the battery bank
is maintained with
a small current and
reduced voltage.
WTL0013
During the installation of the WhisperGen, some system parameters are
set specifically for the particular battery bank that is being used. Before
changing the battery bank to a different type or size, consult your
authorised WhisperGen agent.
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28
Auto-Charging the Battery Bank
You can set the WhisperGen to automatically start and charge the battery bank when the battery
bank charge level is low.
To set the WhisperGen to auto-charge the battery bank:
1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in
section entitled Setting the Maximum Run Time.
2. Press
∨ to scroll down to Auto-charge.
3. Press
> to begin editing the auto-charge setting.
4. Press
∧ to select ON. The AUTOCHARGE indicator lights up.
5. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Auto-charge
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Auto-charge ON
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29
With the Auto-charge option turned ON, the WhisperGen will automatically start whenever the
battery bank charge level falls below a preset level. This “threshold” level is set during the
installation of the WhisperGen according to the needs of your particular application. If you wish to
change it, contact your authorised WhisperGen agent.
The battery bank is typically charged in three stages as described in section entitled Stages of
Charging. Once the battery bank is fully charged, the WhisperGen stops automatically and
returns to the standby mode. Regardless of heat management settings, the WhisperGen will stop
once the battery bank is fully charged if the WhisperGen had been started by the auto-charge
function.
If the WhisperGen was started by the auto-charge function, the Max Run Hours setting does not
affect the operating time of the WhisperGen. Regardless of the Max Run Hours setting, the
WhisperGen will fully charge the battery bank before stopping.
For a summary on operating options, see section entitled Quick Reference - Operating Options.
Bulk-charging the Battery Bank
While the WhisperGen is running, you can start a new cycle of battery bank charging, that is,
return to bulk-charging the battery bank, see section Stages of Charging. This can be done
regardless of auto-charging and heat management settings.
To bulk-charge the battery bank while the WhisperGen is running:
Hold down START on the control panel until a beep is heard. The control panel will display “Bulk
charge”. As an anti-tamper feature, short presses of the START key are ignored.
A new charging cycle, beginning with bulk-charging, as described in section Stages of Charging
will be started.
While the WhisperGen is auto-charging the battery bank, you can stop
it at any time by pressing STOP on the control panel. The WhisperGen
will however immediately start again if the battery bank charge level is
still below the preset level. To prevent the WhisperGen from restarting,
turn the Auto-charge option OFF.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Bulk charge
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30
Managing Heat Generation
Setting the Coolant Temperature
Whenever it is running, the WhisperGen regulates the temperature of the coolant circulating
through it. The coolant is used for space and domestic water heating. By default, the temperature
of the coolant is maintained at approximately 60°C. You may however set the coolant temperature
to any temperature from 45°C to 70°C.
To set the temperature of the coolant:
1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in
section entitled Setting the Maximum Run Time.
2. Press
∨ to scroll down to Temp Setpoint.
3. Press
> to begin editing the coolant temperature setting.
4. Press
∧ or ∨ to select the coolant temperature. The values shown on the control panel are in
°C.
5. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Temp Setpoint
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Temp Setpoint 62
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31
Turning On Heat Management
Whenever it is running, the WhisperGen maintains the coolant temperature at approximately the
set point until the battery bank is fully charged. When the battery bank is fully charged, the
WhisperGen stops and returns to the standby mode and the coolant temperature is no longer
maintained. You can however turn on the heat management option to keep the WhisperGen
running to maintain the coolant temperature continuously even after the battery bank has been
fully charged.
The WhisperGen will continuously maintain the coolant temperature after the battery bank is fully
charged only if the WhisperGen is started manually or from a remote switch. If the WhisperGen
starts as a result of the Auto-charge function, the WhisperGen will stop and return to the standby
mode once the battery bank is fully charged. For more information refer to section entitled Quick
Reference - Operating Options.
To turn on the heat management option:
1. Access the User Menu on the control panel – follow steps 1 to 3 of the procedure outlined in
section entitled Setting the Maximum Run Time.
2. Press
> to begin editing the heat management setting.
3. Press
∧ to turn the Heat Manage option ON. The HEAT MANAGE indicator lights up.
4. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
With the Heat Manage option turned ON, the WhisperGen, if started manually or from a remote
switch, will run continuously and maintain the coolant temperature until it is stopped manually or
from the remote switch. If a Max Run Hours setting of less than 25 has been set, the
WhisperGen will automatically stop when the Max Run Hours set value is reached. See section
Quick Reference for a summary on operating options.
If the Heat Manage option is turned ON and an external water heater is connected to the cooling
circuit of the WhisperGen, the external water heater will be automatically started to give a rapid
initial heat-up of the coolant and to provide supplementary heating whenever required. After the
initial heat-up, the external heater will be turned on only if the WhisperGen is unable to maintain
the coolant temperature at the set point. The temperatures at which the external heater is started
or stopped are preset.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Heat Manage ON
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32
Clearing Faults and Warnings
There are two types of errors that the WhisperGen automatically detects, as described below:
Upon detecting a fault, the WhisperGen will shut down, and then automatically clear the fault and
attempt to restart. By default, the WhisperGen will attempt to restart once. If you wish to change
this setting, contact your authorised WhisperGen agent. Error messages associated with faults
from which the WhisperGen cannot recover by itself need to be cleared before normal operation
of the WhisperGen may be resumed.
To clear an error message:
1. Physically correct the fault – refer to trouble shooting section for more information.
2. Hold down START on the control panel until a beep is heard and the FAULT indicator turns
off. The WhisperGen does not restart automatically. To restart it, see section entitled Starting
the WhisperGen.
A warning can be cleared even if the physical cause of it has not been corrected. It is possible for
the WhisperGen to detect a warning and then subsequently a fault. If this occurs the WhisperGen
will attempt to clear the fault and restart itself, the fault needs to be cleared before the
WhisperGen can be started again. It is however recommended that the cause of the warning be
determined and corrected as soon as possible – see section entitled Trouble Shooting for more
information.
Error Type Meaning Indication
Warning Error that is minor or which
indicates that a fault might be
developing.
• The FAULT indicator on the control panel
flashes while the error exists.
• No error message is displayed on the
control panel.
• The WhisperGen continues operating.
Fault Functional error that causes
the WhisperGen to shut
down.
• The FAULT indicator on the control panel
is constantly lit.
• An error message is displayed on the
control panel.
• The WhisperGen shuts down
automatically.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
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33
When the WhisperGen is started, any warning present is automatically cleared.
To manually clear a warning:
3. Access the main menu on the control panel – follow steps 1 and 2 of the procedure outlined in
section entitled Setting the Maximum Run Time.
4. Press
∨ to scroll down to Fault/Warning Menu.
5. Press
> to display the first item on the Fault/Warning Menu.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Fault/Warning Menu
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Warning Code [102]
Edit to clear
Code of prevailing
Warning
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34
6. Press > to begin clearing the warning.
7. Press
∨ to clear the warning. The Fault indicator turns off.
8. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Warning Code [102]
Edit to clear
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Warning Code [0]
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35
Adjusting the LCD
Adjusting the Contrast
The control panel has a liquid-crystal display (LCD) which shows system information. The
contrast of the LCD can be manually adjusted.
To increase the contrast of the LCD:
Hold down
< and ∧ repeatedly until the desired contrast is achieved.
To decrease the contrast of the LCD:
Hold down
< and ∨ press repeatedly until the desired contrast is achieved.
If the battery bank is disconnected from the WhisperGen, LCD contrast settings are retained for
up to approximately one month after the disconnection.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
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36
Adjusting the Backlight
The LCD has a backlight which allows the LCD to be more clearly seen in dark environments. The
backlighting can be manually adjusted.
To adjust the LCD backlight:
1. Hold down
< and > press repeatedly until the desired level of backlighting is achieved. Three
levels of backlighting are available namely: high, low, and off.
If no keys are pressed, the backlight will be automatically turned off after four minutes. It will be
automatically turned on again when a key is pressed. If the battery bank is disconnected from the
WhisperGen, backlighting settings are retained for up to approximately one month after the
disconnection.
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FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
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Displaying System Information
Available Information
The control panel displays information regarding the status of the WhisperGen system. The
following information, structured as shown in section entitled Quick Reference - Information
Structure, may be obtained from the control panel:
Default Display
Parameter Meaning Typical Range
Battery Volts The voltage across the terminals of the
battery bank.
12V battery bank: 9.5 to 15.5
Volts.
24V battery bank: 19.0 to 31.0
Volts.
Battery Amps The net quantity of electric current in
Amperes, flowing through the battery
bank. Positive values indicate charging
and negative values discharging.
-600 to 200A.
Batt Amp-hrs The state of battery bank discharge in
Ah. A fully charged battery bank is
assigned zero Ah.
-700 to 100Ah.
Battery Watts The quantity of electrical power in Watts
supplied to the battery bank. Positive
values indicate charging and negative
values discharging.
-7000 to 1000 Watts.
Gross Watts The gross electrical power in Watts,
from the WhisperGen generator before
power to auxiliary devices such as the
air blower and pumps.
200 to 1000 Watts.
Runtime (Min) The total operating time in minutes
since starting.
0 to 999,999 minutes.
Hour Meter The cumulative number of hours of
operation since the WhisperGen was
first commissioned. The WhisperGen
must be serviced by an authorised
WhisperGen agent every 12 months or
every 2000 hours of operating time,
whichever comes first.
0 to 999,999 hours.
# Of Starts The cumulative number of times the
WhisperGen has started since it was
first commissioned.
0 to 999,999.
Warning Code The code of the prevailing warning, if
there is one. A flashing FAULT indicator
indicates the presence of a warning.
The flashing will stop if the cause of the
warning disappears.
100 to 199.
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38
User Menu
Parameter Meaning Typical Range
Heat Manage The heat management function – see section
entitled Turning on heat mangement.
ON or OFF (default).
Temp Setpoint The temperature in °C that the coolant is to
be maintained at during operation of the
WhisperGen – see section entitled Setting
the coolant temperature.
45 to 70°C (default is 60°C).
Auto-charge The Auto-charge function – see section
entitled Auto-charging the battery bank.
ON or OFF (default).
Ext. Control The external or remote control function – see
section entitled Remote controlling.
ON or OFF (default).
Ext Control Mode The mode of operation for the external or
remote control switch – see section entitled
Remote controlling.
1, 2 (default), or 3.
Max Run Hours The number of hours of operation after which
the WhisperGen is to stop. This parameter
setting is a “timer” by which the WhisperGen
operates – see section entitled Setting the
maximum run time.
1 to 24 hours, or 25 hours for
continuous operation (default).
Fault/Warning Menu
Parameter Meaning Typical Range
Warning Code
Edit to clear
The current warning code and the warning
clearing function – see section 2.8.
100 to 199.
Current Warning The code of the prevailing warning, if there is
one.
100 to 199.
Last Warning The code of the last warning. 100 to 199.
2nd Last Warning The code of the warning prior to the last. 100 to 199.
Current Fault The code of the prevailing fault, if there is
one.
2 to 99.
Last Fault The code of the last fault. 2 to 99.
2nd Last Fault The code of the fault prior to the last. 2 to 99.
Start Code The code indicating how the WhisperGen
last started. “1” = “manual start”; “2” = “auto-
charge start”; “3” = “external control start”.
1, 2, or 3.
Stop Code The code indicating how the WhisperGen
last stopped. “9” = “fault”; “1” = “manual
stop”; “2” = “battery charge complete”; “3” =
“external control stop”; “4” = “max run hours
exceeded”; “5” = “parallel charger turned on”.
9YY, X1, X2, X3, X4, or X5
where YY is the code of the
prevailing fault and X is the
start code.
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Extra Info Menu
Parameter Meaning Typical Range
Alt Current The electric current in Amperes that is
being generated by the WhisperGen
alternator. Positive values indicate current
generation and negative values current
flow to the WhisperGen from the battery
bank during cranking.
12V: -20 to 75A.
24V: -10 to 37A.
Air % The power applied to the air blower as a
percentage of the maximum power that
can be applied to it. The higher the air flow
rate, the higher the combustion rate.
0 to 100%.
Bus Voltage The voltage across the electrical terminals
of the WhisperGen.
12V: 10 to 15.5V.
24V: 20 to 31V.
Coolant Temp The temperature in °C of the coolant. The
coolant temperature reflects the
temperature of the engine block.
-10 to 85°C.
Clamp Current The excess electric current in Amperes
being diverted into the “clamp”, an electric
water heating element located inside the
WhisperGen enclosure.
0 to 70A.
Clamp Voltage The voltage setting of the “clamp” system.
12V: 12.2 to 16.3V.
24V: 24.85 to 32.7V.
Exhaust Temp The temperature in °C of exhaust gases
between the burner and exhaust heat
exchanger.
-10 to 550°C.
FID Current uA The current in µA flowing between the FID
(flame- ionisation detector) electrode and
the burner shell. A large current indicates a
good stable flame in the burner and correct
FID operation.
0 to 10µA.
Fuel Cut Off The position of the automatic fuel isolation
valve located inside the WhisperGen. It
should be ON when the WhisperGen is
operating.
ON or OFF.
Fuel Metering The operating state of the fuel pump. It
should be ON when the WhisperGen is
operating.
ON or OFF.
Fuel Frequency The rate at which fuel is pulsed into the
burner. The fuel pulse rate is adjusted in
relation to power demand and the air/fuel
ratio.
2 to 16Hz
Glow Plug The operating state of the glow plug. The
glow plug is turned ON as required during
the start-up of the burner.
ON or OFF.
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40
Isolate Relay The position of the main electrical isolator
relay located inside the WhisperGen. It
should be ON when the WhisperGen is
operating.
ON or OFF.
Power Relay The power supply to ancillary components
such as the fuel pump, coolant pump, etc.
The power supply should be ON when the
WhisperGen is operating.
ON or OFF.
O2 Value The quantity of oxygen in the exhaust. This
reflects the air/fuel ratio.
200 to 2500.
O2 Ave Error The averaged difference between the air/
fuel ratio set point and the actual ratio. The
smaller the difference, the more stable the
burner.
2 to 400.
Software Ver The version of software the WhisperGen is
operating on.
A five-digit number.
Installation Menu
Parameter Meaning Typical Range
Heat exchanger
Nozzle Bleed
Spraying water through the heat
exchanger to clean internal cavities.
On for 1 sec.
Air Bleed Blowing air through the burner and
exhaust system.
ON or OFF (default).
Fuel Bleed The fuel bleeding function – see section
entitled Bleeding the Fuel Line. The water
pumps may start when the fuel line is bled.
ON or OFF (default).
Coolant 1 Bleed The coolant bleeding function – see
section entitled Bleeding the Coolant
Circuit.
ON or OFF (default).
Coolant 2 Bleed The seawater and coolant bleeding
function – see section 3.8.
ON or OFF (default).
Enable Starts The function that enables or disables
WhisperGen starts during maintenance or
servicing. “0” = “no starts allowed”; “1” =
“allow manual starts only”; “2” = “allow all
manual and automatic starts”.
0 (default), 1 or 2.
Extra Info Menu
Parameter Meaning Typical Range
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41
Displaying Information
Information displayed on the control panel is structured as shown in the section entitled Quick
Reference - Information Structure. The default display is the highest level on the information
structure. If no keys are pressed for a few minutes, the control panel defaults to the last displayed
parameter on the default display.
To access the default display at any time:
1. Press
< repeatedly until one of the default display parameters appear. For example, if Alt
Current (a parameter of the “extra info” menu) is initially displayed, pressing
< twice returns
to the default display.
To display a menu at a lower level:
2. Press
>. For example, if Battery Volts (a parameter in the default display) is displayed
initially, then to display the main menu, press
> once as shown.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
User Menu
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42
To display a menu at a higher level:
3. Press
<. For example, if Alt Current is displayed initially, then to display the main menu,
press
<.
To scroll up within a menu:
4. Press
∧ . For example, if Bus Voltage is displayed initially, then to display Alt Current, press
∧ twice.
To scroll down within a menu:
5. Press
∨. For example, if Alt Current is displayed initially, then to display Coolant Temp,
press
∨ three times.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Alt Current
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Coolant Temp
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43
Editing Parameter Settings
Information displayed on the control panel is structured as shown in section entitled Quick
Reference. The settings of all the parameters under the User Menu and Installation Menu can
be edited. The Warning Code Edit to clear parameter under the Fault/Warning Menu can also
be edited. All other parameter settings can be displayed but not edited.
To edit the setting of a parameter:
1. Display the parameter on the control panel – see section entitled Displaying System
Information - Displaying Information. For example, if you wish to edit the battery bank auto-
charging setting, then display Auto-charge on the control panel by pressing
> twice followed
by
∨ twice from the default display.
2. Press
> to begin editing the setting of the parameter. The existing setting of the parameter will
be displayed. In the above example, either ON or OFF will be displayed, depending on the
existing setting of Auto-charge.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Auto-charge
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Auto-charge OFF
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44
3. Press ∧ or ∨ to edit the setting. In the above example, if the existing setting is OFF and you
wish to turn on auto-charging, then press
∧ to change the setting to ON.
4. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Auto-charge On
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
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Maintenance
Introduction
This section outlines maintenance procedures for your WhisperGen. It will show you how to:
• Develop a basic maintenance routine for the WhisperGen;
• Maintain the fuel and coolant systems;
• Check the battery bank connections; and
• Replace the glow plug, fuses, FID, oxygen sensor, and evaporator.
Maintenance Schedule
The following maintenance procedures must be performed on the WhisperGen on a regular basis
as recommended below:
In addition to the procedures above, you should also contact your authorised WhisperGen service
agent to check the WhisperGen every 12 months or every 2000 hours of operating time.
Procedure How When
Checking the coolant. See section - Checking the
Coolant.
Depends on the coolant circuit;
at least once a month.
Checking battery bank
connections.
See section - Checking battery
bank connections.
Every three months.
General checking. See section - General
checking.
Every six months.
Flushing the exhaust heat
exchanger
See section - Flushing the
exhaust heat exchanger
Every three months.
You should read and understand all safety precautions before
operating or maintaining your WhisperGen. For spare parts kit
supplied, refer to your authorised WhisperGen service agent for
further details.
Before carrying out maintenance, the Enable Starts option in the
Installation Menu should be set to 0 to prevent unintentional starts of
the WhisperGen. Reset to either 1 or 2 (depending on the user setting
requirement) after maintenance has been completed. For information
on how to edit settings, refer to section entitled Displaying System
Information - Editing Parameter Settings.
If service checks are not performed by an authorised WhisperGen
service agent every 12 months or 2000 hours of operating time from
the date of commissioning, the warranty on the WhisperGen will be
void.
When performing any maintenance work on the WhisperGen, refer to
the applicable sections when removing or replacing parts and
stopping or starting the WhisperGen.
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46
The following procedures may need to be carried out if faults develop:
For all WhisperGen faults and maintenance procedures not listed in this manual, please contact
your authorised WhisperGen service agent for assistance. A list of WhisperGen faults that may
arise and how they may be remedied is given in the Trouble shooting section.
Procedure How When
Bleeding the fuel line. See section - Bleeding the fuel
line.
• When there is air trapped in
the fuel line.
• After a fuel run-out occurs.
• After the fuel filter is
cleaned.
Cleaning the fuel pump filter. See section - Cleaning the fuel
pump filter.
• When fuel supply faults
arise.
• When the power output is
constantly low.
Bleeding the coolant circuit. See section - Bleeding the
coolant circuit.
When there is a coolant flow
fault.
Replacing the glow plug. See section - Replacing the
glow plug.
When a glow plug circuit fault
arises and the glow plug fuse is
not blown.
Replacing fuses. See section - Replacing fuses. When fuses are blown.
Replacing the FID. See section - Replacing the FID When ignition or flame faults
occur repetitively.
Replacing the oxygen sensor. See section - Replacing the
oxygen sensor.
• When oxygen sensor faults
arise.
• If burner or flame faults
occur despite FID
replacement.
Replacing the evaporator. See section - Replacing the
evaporator.
If burner, ignition, or flame
faults occur despite FID and/or
oxygen sensor replacement.
When maintaining or troubleshooting the WhisperGen, you should
perform only the procedures recommended in this manual. If you
perform procedures other than those recommended in this manual,
you may cause injury or equipment damage, and the warranty on the
WhisperGen will be void.
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47
Removing the Enclosure Lid
The enclosure lid protects the internal parts of the WhisperGen and is held in place by two rubber
rings. Some maintenance and troubleshooting procedures require the enclosure lid to be
removed.
To remove the enclosure lid:
1. Remove the rubber rings from the upper plastic hooks on both sides of the WhisperGen.
2. Carefully lift the enclosure lid.
When replacing the lid, hook it over the back of the enclosure base and swing it down over the
front. Ensure the lid is well seated on the rubber seal. Then connect the rubber rings to the
hooks.
WTL0018
WTL0019
Do not touch the surfaces that are labelled as hot and do not operate
the WhisperGen without the enclosure lid on for more than 10 minutes
as air circulation through the WhisperGen will be disrupted.
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General Checking
The following general checking routine helps to ensure the proper functioning of the WhisperGen
and should be performed every six months.
1. Start the WhisperGen.
2. Check that the WhisperGen exhaust does not contain high levels of smoke. When the
WhisperGen first starts, smoke may be released initially. However, only steam should be
visible several minutes after the WhisperGen has started.
3. Check all exhaust piping in occupied areas for leakage. You should not smell fuel fumes in
occupied areas. If in doubt, apply soapy water on exhaust piping joints to check for exhaust
gas leakage.
4. Check all coolant piping for leakage.
5. Check the coolant level.
6. Check all fuel piping for leakage.
7. Remove the WhisperGen enclosure lid.
8. Check for smoke emissions from within the WhisperGen enclosure. There should not be
smoke emitted from inside the WhisperGen and you should not smell diesel fumes.
9. Check for fuel and coolant leakage inside the WhisperGen enclosure. Fluids and white
residue deposited at the bottom of the WhisperGen enclosure are often an indication of
leakage.
10. Check for abnormal noises. There should not be excessive rattling sounds.
11. Check that the rubber hoses and the external red burner seal are not cracked or worn.
12. Check the battery bank connections.
13. Check that the drain holes in the bottom corners of the enclosure base are not blocked.
14. Remove, with a vacuum cleaner, dust accumulated on the inside of the WhisperGen,
particularly on the front louvres of the electronics enclosure.
15. Replace the enclosure lid.
16. Check that the condensate drain hose is clear of debris and obstructions.
If you find any abnormalities, whether inside or outside the WhisperGen, contact your authorised
WhisperGen service agent immediately. The contact details for your authorised WhisperGen
service agent appear at the back of this manual.
The rest of the steps below must be completed in 10 minutes or less.
The WhisperGen should not be operated without the enclosure lid for
prolonged periods.
Do not touch the surfaces that are labelled as hot.
Do not attempt to do any repairs that are not authorised in this
manual.
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49
Checking the Fuel
The fuel level should be checked regularly to ensure a constant fuel supply to the WhisperGen.
How often the fuel needs to be checked and replenished depends on the operating conditions of
the WhisperGen and the size of the fuel tank. In general, the WhisperGen consumes 0.5 to 0.85
litres of fuel per hour of operation. This applies to machines using either diesel or kerosene fuel.
To check the fuel level:
1. Remove the fuel tank cap. The fuel tank is located outside the WhisperGen and is typically
within five metres of it.
2. Ensure that the fuel level is adequate. The fuel level must be higher than the fuel outlet point
at all times.
3. Replenish fuel if necessary, taking care not to spill any on or in the vicinity of the WhisperGen.
For WhisperGen’s equipped with diesel burners.
For WhisperGen’s equipped with kerosene burners.
4. Replace the fuel tank cap.
If the fuel tank was empty and a fuel-related error message is displayed on the control panel, you
will need to bleed the fuel line before the WhisperGen can be operated normally again.
WTL0020
Minimum Inadequate
Outlet Outlet
Fuel
Fuel
Use only good quality automotive diesel (EN590 or BS2869: 2000
burner fuel class A2, D, minimum flash point, closed, 56°C). Do not use
other fuel types such as bio diesel, heating oil, petrol, aviation fuel,
and LPG.
Use only good quality kerosene oil (BS2869: 2000 class C1, or C2
burner fuel, minimum flash point, closed, 43°C for C1, 38° C for C2).
Do not use other fuel types such as heating oil, petrol, aviation fuel,
and LPG.
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50
Bleeding the Fuel Line
To bleed the fuel line:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
2. Remove the enclosure lid and wait for the engine to cool.
3. Turn on the WhisperGen fuel valve.
Filling a fuel tank that has run empty may introduce into the fuel line
air bubbles that could cause the WhisperGen to malfunction. After
filling an empty fuel tank, you must bleed the fuel line to remove any
air bubbles that might be trapped in it.
The coolant and seawater pumps may start when the fuel line is bled.
(marine version only)
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
FUEL OFF
ON
WTL0011
OFF
ON
FUEL
R
Personal Power Station
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51
4. Uncrew the fuel line fitting on top of the burner.
5. Connect a clear plastic hose to the exposed end of the fuel line, and allow the hose to drain
into a container that will hold at least a litre of fuel.
6. Access the Main Menu on the control panel - follow the first two steps of the procedure
outlined in the section entitled Stopping the WhisperGen - Setting the maximum run time.
7. Press
∨ to scroll down to Installation Menu.
2
WTL0022
WTL0023
Fuel Container
Plastic
Hose
Fuel Line
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Installation Menu
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52
8. Press > to display the third item on the Installation Menu, Fuel Bleed.
9. Press
> to begin editing the fuel bleeding setting.
10. Press
∧ to select ON. Fuel will be bled through in pulses for 60 minutes. You can stop the fuel
pump at any time by pressing
∨. At least twice the volume of fuel in the entire fuel line
connecting the fuel tank to the evaporator must be bled. For example, if the fuel line measures
3mm in inner-diameter and 5m in length, then 70ml of fuel must be bled.
11. Optional: press < repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
12. Reconnect the fuel line to the evaporator. Finger tighten the nut against the shoulder. Using a
spanner tighten ¾ turn only.
13. Ensure that there is no leakages.
14. Replace the enclosure lid.
The WhisperGen may now be started as required.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Fuel Bleed
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Fuel Bleed ON
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53
Cleaning the Fuel Pump Filter
Fuel supplied to the WhisperGen must have low levels of contamination. The fuel filter inside the
fuel pump should be cleaned if faults related to fuel supply occur frequently or if the power output
is constantly low.
To clean the fuel filter:
1. Turn off the fuel tank valve and the WhisperGen fuel valve.
2. Place a container below the fuel pump to collect fuel spillage.
3. Remove the fuel line from the brass end of the fuel pump.
4. Undo the cylindrical brass fitting.
Fuel Tank
Fuel Tank
Valve
Auxiliary
In-line
Filter
Fuel
Pump
OFF
ON
FUEL
WTL0025
Fuel
Pump
WTL0026
WTL0027
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5. Remove the filter from the fuel pump.
6. Clean the filter by either blowing clean compressed air through it or by brushing it in clean
diesel or kerosene. Do not use a cloth rag to clean or dry the filter
.
7. Replace the filter in the brass fitting and secure the brass fitting to the fuel pump, making sure
that the o-ring is correctly seated.
8. Secure the fuel line to the fuel pump.
9. Turn on the fuel tank and WhisperGen fuel valves.
10. Bleed the fuel line.
11. Check that there is no fuel leakage.
If there is another fuel filter installed external to the fuel pump, it should be cleaned also – follow
the instructions provided by the WhisperGen service agent who installed the external filter.
WTL0028
WTL0029
Fuel Filter
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Checking the Coolant
The coolant level should be checked regularly to ensure a constant circulation of coolant through
the WhisperGen. How often the coolant needs to be checked and replenished depends on the
size of the coolant header tank and the coolant circuit. In general, you should check the coolant
level at least once a month.
To check the coolant level:
1. Remove the coolant header tank cap. The WhisperGen coolant header tank is located outside
the WhisperGen and is typically mounted at a level above the WhisperGen.
2. Ensure that the coolant level is adequate. The coolant level must be higher than the outlet
point at all times.
3. Replenish coolant if necessary. Use a high-quality automotive glycol-based corrosion-
inhibited antifreeze that is designed for aluminium engines. Follow the dilution
recommendation of the manufacturer.
4. Replace the coolant header tank cap.
The cooling system of the WhisperGen is vital to its performance. If the
coolant level is not maintained correctly, damage may occur.
WTL0030
Minimum
Inadequate
Outlet
Coolant
(cold)
Coolant
Inlet
Outlet
Inlet
Ethylene glycol is harmful if swallowed or inhaled. Do not store it in
open or unlabelled containers. Wash your hands thoroughly after
handling it.
Using an incorrect type of coolant can cause serious corrosion in the
WhisperGen – use only the recommended coolant.
Ensure that the coolant is free of particulate contaminants. Foreign
particles in the coolant can obstruct coolant passages in the engine,
resulting in damage to the WhisperGen.
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56
Bleeding the Coolant Circuit
To bleed the coolant circuit:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
2. Remove the enclosure lid and wait for the engine to cool.
3. Access the Main Menu on the control panel - follow the first two steps of the procedure
entitled Setting the Maximum Run Time.
4. Press
∨ to scroll down to Installation Menu.
Filling a coolant header tank in which the coolant level has fallen below
the outlet level of the tank, may introduce into the coolant circuit air
bubbles that could cause the WhisperGen to malfunction. Should this
occur bleed the coolant circuit.
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Installation Menu
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57
5. Press > to display the first item on the Installation Menu.
6. Press
∨ to scroll down to Coolant Bleed 1.
7. Press > to begin editing the coolant bleed setting.
8. Press
∧ to select ON. the coolant pump will be turned on to bleed the coolant circuit.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Hx Nozzle Bleed
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Coolant Bleed 1
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Coolant Bleed 1 ON
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58
9. Get a clean rag ready.
10. Open the coolant-bleeding valve with a 6mm hex socket (or with a suitable key). Use the rag
to absorb the coolant bleeding out.
11. After the coolant pump has been running for five minutes, press
∨ to turn it off.
12. Allow the coolant to rest for one minute.
13. Repeat steps 8 to 12 until coolant bleeds out of the coolant-bleeding valve without air bubbles.
14. Close the coolant-bleeding valve securely.
WTL0031
Oxygen
Sensor
Exhaust
Heat
Exchanger
Coolant-Bleeding
Valve
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Coolant Bleed 1 OFF
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59
15. Repeat steps 3 to 7 to begin editing the coolant pump setting, and then press ∨ to turn off the
coolant pump
.
16. Optional: press < repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
17. Replace the enclosure lid.
The WhisperGen may now be started as required.
The information below applies to marine units only.
The seawater circuit may need to be bled if the seawater pump inlet has been lifted above
seawater level. To bleed the seawater circuit, follow steps 1, 3, 4, 5, 6, 7, and 8 above but turn on
Coolant Bleed 2 instead of Coolant Bleed 1 in the Installation Menu. The seawater pump –
and the coolant pump – will be turned on to bleed both the seawater and coolant circuits for one
hour after which the pumps will automatically stop. You can also stop the pumps at any time by
pressing
∨.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Coolant Bleed 1 OFF
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60
Checking Battery Bank Connections
Power flows between the WhisperGen and battery bank via two power cables connected to the
terminals of the battery bank. The WhisperGen also monitors the battery bank voltage, current,
and temperature via electrical wires connected to the battery bank. If an electrical fault or warning
occurs, these electrical connections may need to be checked – refer to the trouble shooting
section. In general, the battery bank connections should be checked every three months.
To check the battery bank connections:
1. Access the battery bank managed by the WhisperGen, and ensure that the battery bank
connections, as shown below, are intact and clean.
2. Check that the circuit breaker is closed.
3. Replace the voltage fuse if it has blown.
4. Check that the electrical insulation of the wires/cables is intact.
5. Remove the enclosure lid.
FUEL OFF
ON
Current Shunt
Current Sensing
Wires
Power Cables
Voltage Fuse
White
No assigned colour
No assigned colour
Green
Black
Violet
Red
Circuit
Breaker
Voltage
Sensing
Wires
Temperature
Sensor
(Optional)
Battery Bank
WTL0032
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Do not touch the surfaces that are labelled as hot.
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61
6. Check that the electrical connections on the side of the electronics enclosure, as shown
below, are intact. Before re-securing a wire/cable, first stop the WhisperGen and disconnect
the WhisperGen from the battery bank by opening the circuit breaker.
7. Replace the enclosure lid. If you had disconnected the WhisperGen from the battery bank,
reconnect it by closing the circuit breaker.
If an electrical fault persists or if the electrical insulation of the wires/cables is worn, contact your
authorised WhisperGen service agent.
If stopping the WhisperGen to re-secure a wire/cable, heed the warning
given at the beginning of this section to prevent unintentional starts of
the WhisperGen.
FUEL OFF
ON
2
WTL0033
Green
White
Red
Black
Violet
Current Sensing
Wires
Power Cables
(No Assigned Colour)
Voltage Sensing
Wires
Temperature
Sensing Wires
(Optional)
7891011
7
8
9 10111213141516171819
1
2
3
4
56
Phœnix
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62
Replacing the Glow Plug
Should a “Glowplug cct fault” error message be displayed on the control panel, and the glow plug
circuit fuse is intact, it may be necessary to replace the glow plug. In general, you should check
the glow plug circuit fuse before deciding to replace the glow plug.
To replace the glow plug:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
2. Remove the enclosure lid and wait for the engine to cool.
3. Remove the nut on top of the glow plug and detach the wire.
4. Unscrew the glow plug using a 22mm (spark-plug size) spanner.
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
WTL0034
Evaporator
Glow Plug
Glow Plug
Wire
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63
5. Remove the glow plug.
6. Insert a new glow plug with a washer into the evaporator and fasten the glow plug securely
with a torque of 20 to 25Nm.
7. Replace the wire terminal and washer on the threaded tip of the glow plug and fasten the nut
securely.
8. Replace the enclosure lid.
The old glow plug can be returned to your authorised WhisperGen service agent for checking.
The glow plug may be hot.
WTL0035
Glow Plug
Do not touch the wire coil on the new glow plug, as this will shorten
its life span.
It is advisable to keep a spare glow plug with the WhisperGen at all
times.
Glow plugs used on the WhisperGen should be obtained from
authorised WhisperGen agents.
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Replacing Fuses
Replacing the Battery Bank Voltage Fuse
The WhisperGen detects the voltage of the battery bank via two wires connected to the terminals
of the battery bank as shown below. If the battery bank voltage displayed on the control panel is
abnormal, it may be that the fuse in the circuit has blown.
To replace the battery bank voltage fuse:
1. Unscrew the fuse holder.
2. Replace the faulty fuse.
3. Fasten the fuse holder.
WhisperGen fuses can be obtained from electrical hardware suppliers or your authorised
WhisperGen service agent
.
Before replacing a fuse, find out the cause of the fault. Otherwise,
damage to equipment may occur. If you are unsure of the cause of the
fault, contact your authorised WhisperGen service agent for assistance.
FUEL OFF
ON
Voltage Fuse
Voltage
Sensing
Wires
Fuse Holder
(Fuse Inside)
WTL0036
R
Personal Power Station
Ensure that the replacement fuse is of a similar type (Ø0.25 x 1.25
inch, or Ø6.35 x 31.75mm) and of the correct current rating (2.00A). It
is advisable to keep spare fuses with the WhisperGen at all times.
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65
Replacing Other Fuses
The WhisperGen has fuses that protect against overloading of its electrical circuits. If a circuit is
overloaded, the fuse will blow and the WhisperGen will shut down with the fault indicated on the
control panel.
To replace a fuse (other than the battery bank voltage fuse):
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit, then
remove the enclosure lid.
2. Disconnect the WhisperGen from the battery bank by opening the circuit breaker.
3. Release the four screws securing the cover of the electronics enclosure and remove the
cover.
Before replacing a fuse, find out the cause of the fault. Otherwise,
damage to equipment may occur. If you are unsure of the cause of the
fault, contact your authorised WhisperGen service agent for assistance.
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
FUEL OFF
ON
2
WTL0052
Electronics
Enclosure
Cover
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66
4. Remove the appropriate fuse and check if it has blown. The fuses are located at the bottom of
the electronics enclosure and are marked with their current ratings in Ampere. Error codes
displayed on the control panel help identify which circuit and therefore which fuse may
possibly have blown.
5. Replace the faulty fuse.
6. Replace the electronics enclosure cover and fasten the four screws.
7. Replace the enclosure lid.
8. Reconnect the WhisperGen to the battery bank by closing the circuit breaker.
WhisperGen fuses can be obtained from electrical hardware suppliers or your authorised
WhisperGen service agent.
Current Rating
in Ampere
External / Auxillary
Seawater Pump &
Coolant Pump Circuits
Internal Coolant Pump
Circuit
Fuel Pump & Fuel
Shut-off Valve Circuits
Air Blower, Oxygen Sensor,
& Flushing Circuits
Control Panel &
Microcomputer Circuits
Glow Plug Circuit
WTL0038
32A
15
3
5
10
3
Ensure that the replacement fuse is of a similar type and of the correct
current rating.
It is advisable to keep spare fuses with the WhisperGen at all times.
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67
Replacing the FID
The condition and vertical position of the flame ionisation detector (FID) should be checked if
error codes 58, 59, 60, 61, or 62 occur repetitively.
To check and/or replace the FID:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
2. Remove the enclosure lid and wait for the engine to cool.
3. Undo the screw on top of the FID and detach the wire.
4. Undo the screw that secures the FID clip to the evaporator.
5. Lift the FID out of the evaporator, gripping the FID below the brass nut with a pair of pliers if
necessary. Twist the FID from side to side while pulling it straight up.
6. Check the FID for cracks and that the electrode tip at the bottom of the FID is protruding by at
least one millimetre. Also check that there is electrical continuity between the brass nut and
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
It is important not to twist the brass nut on the FID as this may
damage the FID.
WTL0039
Evaporator
Glow Plug
FID
Evaporator
FID
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68
the electrode tip. If the FID is cracked, has less than one millimetre of the electrode
protruding, or has electrical discontinuity, it should be replaced with a new one. Otherwise, the
FID is re-usable.
7. Insert a straight length of rigid wire vertically into the FID hole. The wire should go down 135 ±
10mm.
8. With the wire touching the base of the FID hole, mark on the wire the top level of the
evaporator.
WTL0040
Replace if
cracked
Replace if
less than
1mm
Replace if
there is electrical
discontinuity
(open circuit)
WTL0041
Evaporator
Wire
WTL0042
Evaporator
Wire
Mark here
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69
9. Lift the wire up by 6mm (no less than 5mm and no more than 8mm) and put a second mark on
the wire at the top level of the evaporator.
10. Remove the wire from the evaporator and move the FID clip so that the distance from the clip
to the electrode tip is the same as the distance from the second mark on the wire to the
bottom tip of the wire. To move the clip, wedge it open slightly with a screwdriver.
11. Without shifting the vertical position of the clip, insert the FID into the FID hole, gripping the
FID below the brass nut with a pair of pliers if necessary. Twist the FID from side to side while
pushing it straight down.
12. Fasten securely the FID clip to the evaporator, and the wire terminal to the FID.
13. Replace the enclosure lid.
The WhisperGen may now be started as required.
WTL0043
Evaporator
Wire
Second mark
First mark
6 mm
WTL0044
FID clip
Move clip here
FID
Wire
Second mark
First mark
Electrode Tip
Bottom Tip
It is important not to twist the brass nut on the FID as this may damage
the FID.
It is advisable to keep a spare FID with the WhisperGen at all times.
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70
Replacing the Oxygen Sensor
The oxygen sensor should be replaced if error codes 10, 14, 56, 60, 61, 62, or 76 occur
repetitively. In general, you should check the FID before deciding to replace the oxygen sensor.
To replace the oxygen sensor:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit.
2. Remove the enclosure lid and wait for the engine to cool.
3. Detach the electrical connector of the oxygen sensor by squeezing the two side clips.
4. Undo the nut that holds the oxygen sensor in place.
To prevent unintentional starts of the WhisperGen, heed the warning
given at the beginning of this section.
Do not touch the surfaces that are labelled as hot.
WTL0045
Oxygen
Sensor
Exhaust
Heat
Exchanger
Electrical
Connector
WTL0046
Nut
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71
5. Remove the oxygen sensor.
6. Insert a new oxygen sensor into the oxygen sensor hole. Note: the ferrules should already be
set in position on the oxygen sensor. The ferrules should be distanced 60mm from the
sensing tip of the oxygen sensor.
7. Finger tighten the nut that holds the oxygen sensor in place. Using a spanner tighten 1¼ turns
only.
8. Re-fit the electrical connector.
9. Replace the enclosure lid.
The WhisperGen may now be started as required.
WTL0047
Do not touch the sensing tip of the oxygen sensor, as this will shorten its
life span.
WTL0048
Do Not
Touch Here
It is advisable to keep a spare oxygen sensor with the WhisperGen
at all times.
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72
Replacing the Evaporator
The evaporator should be replaced if error codes 10, 58, 59, 60, 61, or 62 occur repetitively. In
general, you should check and/or replace the FID and oxygen sensor before deciding to replace
the evaporator.
To replace the evaporator:
1. Remove the FID.
2. Remove the glow plug.
3. Turn off the WhisperGen fuel valve.
4. Unscrew the fuel line fitting on top of the burner.
FUEL OFF
ON
WTL0012
OFF
ON
FUEL
R
Personal Power Station
2
WTL0022
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73
5. Undo the four screws on top of the evaporator.
6. Lift the evaporator out of the burner.
7. Place the evaporator gasket on the new evaporator, ensuring that all the holes line up.
WTL0049
Evaporator
(top view)
Burner
WTL0050
WTL0051
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74
8. Insert the new evaporator with the gasket into the burner and secure the four screws.
9. Check that the FID slides freely into the burner. If necessary, loosen the four evaporator
screws and readjust the position of the evaporator before re-tightening them.
10. Refit the glow plug.
11. Reconnect the fuel line to the evaporator. Finger tighten the nut against the shoulder. Using a
spanner tighten ¾ turn only.
12. Ensure that there is no leakages.
13. Refit the FID.
14. Bleed the fuel line. Refer to section entitled - Bleeding the Fuel Line.
15. Replace the enclosure lid.
16. Turn on the WhisperGen fuel valve.
The WhisperGen may now be started as required. The old evaporator can be returned to your
authorised WhisperGen service agent for servicing.
The evaporator should be serviced by an authorised WhisperGen service
agent only. Do not attempt to do it yourself.
It is advisable to keep a spare evaporator with the WhisperGen at all
times.
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75
Flushing the Exhaust Heat Exchanger
The exhaust heat exchanger should be kept free from blockages to ensure optimum performance
of the WhisperGen. In general you should flush the exhaust heat exchanger at least every 3
months.
To flush the exhaust heat exchanger:
1. Stop the WhisperGen and wait until the STANDBY indicator on the control panel is lit. Refer
the section entitled Stopping the WhisperGen.
2. To access the Main Menu on the control panel - follow the first two steps of the procedure
outlined in the section entitled Stopping the WhisperGen - Setting the maximum run time.
3. Press
∨ to scroll down to Installation Menu.
4. Press
> to display the first item on the installation menu, heat exchanger nozzle bleed.
If the exhaust heat exchanger becomes blocked the performance of the
WhisperGen will decrease.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Installation Menu
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Hx Nozzle Bleed
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76
5. Press ∨ to scroll down to heat exchanger nozzle bleed.
6. Press
> to begin editing the heat exchanger bleed setting.
7. Press
∧ to select ON, then press < to begin flushing the exhaust heat exchanger. Flushing
will continue for 10 seconds.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Hx Nozzle Bleed
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Hx Nozzle Bleed ON
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77
8. Once the heat exchanger bleed shows OFF repeat steps 6 and 7 two more times.
This flushes the system a total of 3 times.
9. Optional: press
< repeatedly to return to the default display. You can also let the default
display re-appear automatically by allowing a few minutes of inactivity on the control panel.
The WhisperGen may now be started as required.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Hx Nozzle Bleed OFF
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
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78
Trouble Shooting
The WhisperGen automatically alerts the user to most errors. Errors may be faults or warnings. If
a fault occurs, the WhisperGen will automatically clear the fault and attempt to restart. By default,
the WhisperGen will attempt to restart once. If you wish to change this setting, contact your
authorised WhisperGen agent.
This section outlines faults and warnings that you may encounter and need to correct. After a fault
is physically corrected, the error message displayed on the control panel needs to be cleared
before normal operation may be resumed. Although a warning can be cleared without the
physical cause being first removed, it is recommended that the cause be determined and
removed at the earliest opportunity. Refer to section entitled Clearing Faults and warnings for
more information.
If you need assistance, please contact your authorised WhisperGen service agent.
Correcting Faults
Code Error Message Likely Cause and Recommended Action
2 Exh overtemp Likely cause:
Low gas pressure and/or burner seal has failed.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
4 Block overtemp Likely cause:
Insufficient cooling of the engine block.
Recommended Action:
Check coolant level. Check for obstructions in coolant and
seawater circuits. Allow engine to cool and restart.
6 Heatsink
overtemp
Likely cause:
Excessive power loss in electronic assembly, or poor air-cooling
within electronics enclosure.
Recommended Action:
Ensure ambient temperature is below 40°C. Ensure airflow from
the base of the enclosure through to the electronics heat sink is
not blocked. Ensure the enclosure lid is fitted and well sealed.
Restart.
7 Electronics too
hot
See 6.
8 Waterflow
stopped
This error only appears when the flow switch monitoring
software is enabled.
You should read and understand all safety precautions before
operating or maintaining your WhisperGen.
When remedying WhisperGen faults, please follow the recommendations in
this manual otherwise, you may injure yourself and the warranty will be
void. If the recommended action does not remedy the fault, contact your
authorised WhisperGen service agent.
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79
12 Air supply fail Likely cause:
Air blower tachometer signal out of range, obstruction of
impeller, or electrical fault.
Recommended Action:
Check connections and presence of any obstructions. Restart.
14 O2 sensor failure Likely cause:
Absence of normal signal from oxygen sensor, or faulty oxygen
sensor.
Recommended Action:
Check connections, replace oxygen sensor if fault continues.
Restart.
16 Fuse/Daisy Ch fail Likely cause:
Electrical or thermal fuse blown, or break in burner safety circuit.
Recommended Action:
Check for high water temperature, high internal temperature.
Check for blown fuses and restart. If restarting fails, check
coolant level and allow engine to cool before restarting.
18 Low batt volts Likely cause:
Insufficient voltage to start the WhisperGen.
Recommended Action:
Check condition of battery bank and terminals. If restarting fails,
check the batteries. Replace faulty batteries and restart.
19 High batt volts Likely cause:
Battery higher than 18 or 36 volts.
Recommended Action:
Check condition of battery bank and terminals.
20 Bus not charged Likely cause:
Fault in electronics assembly or in battery bank voltage sensing
wires.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
24 Isolator open Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
28 Stuck flowswitch This error only appears when the flow switch monitoring
software is enabled.
30 Low batt volts See 18.
32 Bus not charged See 20.
34 Isolator stuck on Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
35 Low batt volts See 18.
Code Error Message Likely Cause and Recommended Action
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80
36 Glowplug cct fault Likely cause:
Glow plug faulty and/or glow plug fuse blown.
Recommended Action:
Check glow plug fuse. If the fuse is intact, replace the glow plug
and restart. If the fuse is blown, replace both the glow plug and
fuse.
38 Bus not charged See 20.
40 Isolator open Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
44 Fuel sense fail Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
46 Flame sense fail Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
48 Drive bridge fail Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
52 Fuel supply fail Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
54 Flame sense fail See 46.
56 O2 sensor fail Likely cause:
Oxygen sensor signal not within expected range.
Recommended Action:
Check connectors and restart. Replace oxygen sensor if fault
continues.
58 Ignition failure Likely cause:
No proper flame signals within two minutes after ignition.
Recommended Action:
Check fuel level, fuel valve, and fuel filter. Restart. Replace FID
if fault continues. Restart. Replace evaporator if fault continues.
59, 60, 61,
62
Flame failure Likely cause:
Loss of flame after ignition.
Recommended Action:
Check fuel level, fuel valve, and fuel filter. Restart. Replace FID
if fault continues. Restart. Replace oxygen sensor if fault
continues. Restart. Replace evaporator if fault continues.
Code Error Message Likely Cause and Recommended Action
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81
64 Heatup failure Likely cause:
Failure to reach cranking temperature within eight minutes.
Thermocouple failure or poor flame strength.
Recommended Action:
Check fuel level, fuel valve, and fuel filter. Check exhaust for
blockage. Attempt to restart, contact an authorised WhisperGen
service agent if problem reoccurs.
66 Crank failure Likely cause:
Unsuccessful crank attempt, probably due to an electrical fault.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
68 Engine sluggish Likely cause:
Low power output after cranking, possibly due to low gas
pressure.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
72 Drive bridge fail Likely cause:
Abnormal electrical condition.
Recommended Action:
Attempt Restart, contact an authorised WhisperGen service
agent if problem reoccurs.
74 Low engine power Likely cause:
Low power output, possibly due to low gas pressure. Low fuel
flow.
Recommended Action:
Check fuel level, fuel valve, and fuel filter. Check exhaust for
blockage. Flush heat exchanger. Restart, if problem reoccurs
contact an authorised WhisperGen service agent .
76 O2 sensor OOL Likely cause:
Oxygen sensor reading out-of-limits, possibly resulting in poor
combustion.
Recommended Action:
Check connector and restart. Replace oxygen sensor if fault
continues.
80 Clamp failed on Likely cause:
Abnormal electrical condition.
Recommended Action:
Contact authorised WhisperGen service agent.
82 Excess volt drop Likely cause:
Too high electrical resistance between the WhisperGen and
battery bank.
Recommended Action:
Check battery bank connections and battery bank voltage
sensing wires. Restart.
Code Error Message Likely Cause and Recommended Action
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82
Correcting Warnings
Although a warning can be cleared without the physical cause being first removed, it is
recommended that the cause be determined and removed at the earliest opportunity. Warnings
are indicated by a flashing FAULT indicator. No error message is displayed.
83 Battery overtemp Likely cause:
Battery bank temperature too high for safe charging.
Recommended Action:
Check battery bank connections and ventilate battery bank
compartment. Restart.
84 Clamp failed off Likely cause:
Abnormal electrical condition, possibly resulting in raised battery
voltage.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
85 High batt volts Likely cause:
Battery bank voltage above normal charging limits.
Recommended Action:
Check settings of any parallel charger connected to the battery
bank. Restart.
90 Clamp control flt Likely cause:
WhisperGen unable to maintain correct battery charging
voltage.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service
agent if problem reoccurs.
92 ParChg V too high Likely cause:
WhisperGen operating voltage has gone too high, in an effort to
avoid conflict with a parallel charger.
Recommended Action:
Check voltage settings of other chargers connected to the
battery bank. Restart.
Code Likely Cause and Recommended Action
102
Likely cause:
Exhaust gas hotter than normal, possibly due to low engine gas pressure.
Recommended Action:
Attempt to restart, contact an authorised WhisperGen service agent if problem
reoccurs.
Code Error Message Likely Cause and Recommended Action
When remedying WhisperGen warnings, please follow the
recommendations in this manual otherwise, you may injure yourself and
the warranty will be void. If the recommended action does not remedy the
warning, contact your authorised WhisperGen service agent.
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83
104
Likely cause:
Engine coolant hotter than normal.
Recommended Action:
Check coolant level. Check coolant and seawater circuits for obstructions. Check
pumps for operation.
107
Likely cause:
Temperature in electronics enclosure abnormally high.
Recommended Action:
Ensure ambient temperature is below 40°C. Ensure airflow from the base of the
enclosure through to the electronics heat sink is not blocked. Ensure the enclosure
lid is fitted and well sealed
126
Likely cause:
Controller is reset while engine is running or engine is hot. This could be the result of
a bad contact between the WhisperGen and the control panel.
Recommended Action:
New cable.
135
Likely cause:
Low battery bank voltage.
Recommended Action:
Check battery bank connections and battery bank voltage sensing wires. Set a
higher value for Max Run Hours and/or turn Auto-charge option ON.
182
Likely cause:
Excessive voltage drop in cabling to battery bank.
Recommended Action:
Check battery bank connections and cables.
183
Likely cause:
Battery bank temperature is high.
Recommended Action:
Check battery bank connections and ventilate battery bank compartment.
190
Likely cause:
Battery bank voltage is unstable during charging.
Recommended Action:
Check battery bank connections and cables.
195
Likely cause:
Battery bank is discharged below a preset level.
Recommended Action:
Start the WhisperGen if it is not operating. Reduce electrical load on the battery
bank. Set a higher value for Max Run Hours and/or turn Auto-charge option ON.
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84
Resetting the WhisperGen
Resetting the control Panel
Due to unusual circumstances, the control panel may sometimes display an incoherent message.
If this happens, the control panel should be reset.
To reset the control panel:
1. Hold down < for at least six seconds. A beep will be heard and the control panel will return to
the default display, indicating normal operation.
Resetting the Electronics Hardware
In some cases, extreme electrostatic interference may cause the WhisperGen to become
unresponsive to key presses on the control panel. If this happens, the WhisperGen electronics
hardware should be reset as soon as possible to ensure that the battery bank is kept charged.
To reset the WhisperGen electronics hardware:
1. Remove the enclosure lid.
When performing trouble shooting tasks on the WhisperGen, refer to
the applicable section(s) when removing or replacing parts.
R
FAULT
AUTOCHARGE
EXT CONTROL
HEAT MANAGE
STOPPING
RUNNING
STARTING
STANDBY
STOP
START
WTL0006
Battery Watts 563
Do not touch the surfaces that are labelled “Hot Surface”.
R
85
2. Remove the four screws in front of the electronics enclosure. Then remove the electronics
enclosure cover.
3. Unplug and then re-plug in the second fuse from the bottom - the fuse that has a current rating
of 3A.
4. Check that the WhisperGen is responsive to key presses on the control panel. If the control
panel display was completely blank, it may be that the fuse was blown. In such a case, check
the fuse and if it has blown, replace it with a new one.
5. Replace the electronics enclosure cover and fasten the four screws.
6. Replace the enclosure lid.
FUEL OFF
ON
2
WTL0052
Electronics
Enclosure
Cover
WTL0053
32A
15
3
5
10
3
Ensure that the replacement fuse is of a similar type and of the correct
current rating.
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86
Service Details
Authorised WhisperGen service agents who commission and/or service the WhisperGen should
fill in this section.
The duplicate copy of the commissioning details should be detached and returned to your
authorised service agent within 14 days of the commissioning date.
Commissioning
Engine Serial No.
Software Version
Commission Date
Commission Date Customer’s Address
Heat Manage Temp Setpoint Auto-charge
Ext. Control Ext Cont Mode Max Run Hours
Battery Capacity Max Batt Disch Tail Current
Absorption Voltage Float Voltage Time Above 14V
SelfDisch/Mth Hour Meter # Of Starts
Agent
’s Stamp Other Remarks
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87
Duplicate
Important: Transcribe details from the last page to this page. Then detach this sheet and return it
to your authorised service agent within 14 days of the commissioning date.
Engine Serial No.
Software Version
Commission Date
Commission Date Customer’s Address
Heat Manage Temp Setpoint Auto-charge
Ext. Control Ext Cont Mode Max Run Hours
Battery Capacity Max Batt Disch Tail Current
Absorption Voltage Float Voltage Time Above 14V
SelfDisch/Mth Hour Meter # Of Starts
Agent
’s Stamp Other Remarks
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88
Servicing
Date / Hours Description of Work Done Agent’s Stamp
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
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89
Date / Hours Description of Work Done Agent’s Stamp
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
DD MM YY
/ /
Hour Meter
Reading
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90
EC Conformity
Manufacturer: Whisper Tech Ltd.,
224 Armagh Street
P.O. Box 13-705
Christchurch
New Zealand
Declares herewith that the WhisperGen PPS16 units:
Comply with the relevant requirements of the following EC directives:
Comply with the relevant requirements of the following national standards and
specifications:
98/37/EC Machinery directive
89/336/EC, 92/31/EC, 98/13/EC EMC directive
Harmonised standards
EN292-1 1991 Safety of machinery – basic concepts, general principles for design –
basic terminology, methodology.
EN292-2 A2 1997 Basic concepts, general principles for design – technical principles
and specifications.
EN294 A2 1993 Safety of machinery – safety distances to prevent danger zones being
reached by upper limbs.
EN563 A1 1995 Safety of machinery – temperatures of touchable surfaces –
ergonomics data to establish temperature limit values for hot surfaces.
EN1050 1996 Safety of machinery – principles for risk assessment.
EN50082-1 1997 Electromagnetic compatibility – generic immunity standard. Part 1.
Residential, commercial and light industry.
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91
This declaration issued by: Bill Highet
General Manager
Whisper Tech Ltd.
Date of issue:
February, 2002
Place of issue: Christchurch, New Zealand.
Non-Harmonised
standards
BS799-2 1991 Specification for vaporising oil burners.
BS5500 1997 Unfired fusion welded pressure vessels.
ISO8528-10 1999 Reciprocating internal combustion engine driven alternating
current generating set – Part 10: measurement of airborne noise.
IEC 61000-4-2 1998 EMC Part 4: testing and measurement techniques. Section 2:
electrostatic discharge test – basic EMC publication.
IEC 61000-4-3 1995 EMC Part 4: testing and measurement techniques. Section 3:
radiated, radio frequency, electromagnetic field immunity test.
IEC 61000-4-4 1995 EMC Part 4: testing and measurement techniques. Section 4:
electrical fast transient burst immunity test – basic EMC
publication.
IEC 61000-4-5 1995 EMC Part 4: testing and measurement techniques. Section 5:
surge immunity test.
IEC 61000-4-6 1996 EMC Part 4: testing and measurement techniques. Section 6:
immunity to conducted disturbances, induced by radio frequency
fields.
IEC 61000-4-11 1994 EMC Part 4: testing and measurement techniques. Section 11:
voltage dips, short interruptions and voltage variations immunity
test.
ENV 50204 1996 Radiated electromagnetic field from digital radio telephones –
immunity test.
CISPR 22 1997 Information technology equipment – radio disturbance
characteristics – limits and methods of measurement.
92
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Index
Absorption-charging 27
Air blower 8, 9
Application 3, 4, 5
Auto-charging 28
Backlighting of LCD 36
Battery bank 1, 27, 60, 64
Battery bank voltage fuse 60, 64
Bleeding coolant circuit 56
Bleeding fuel line 50
Bleeding seawater circuit 56
Bulk-charging 27, 29
Burner 2, 8, 9, 51
CE conformity 90
Charging battery bank 27
Charging stages 27
Checking battery bank connections 60
Checking coolant level 55
Checking fuel level 49
Checking in general 48
Circuit breaker 3, 4, 5
Clamp 39
Cleaning fuel filter 53
Clearing faults and warnings 32
Codes for faults and warnings 78
Commissioning details 86
Control panel 3, 4, 5, 8, 9
Coolant level checking 55
Coolant pump 3, 4, 5, 56
Coolant temperature 30
Correcting faults 78
Correcting warnings 82
Current shunt 3, 4, 5, 60
Displaying parameter settings 41
Earthing strap 8, 9
EC conformity 90
Editing parameter settings 43
Electronics enclosure 8, 9, 64, 82
Emergency stopping 21
Enclosure 8, 9
Error codes 78
Evaporator 62, 72
Exhaust heat exchanger 8, 9
External control 25
Fault 32, 78
Fault clearing 78
Fault codes 78
Fault correcting 78
Flame ionisation detector(FID) 8, 9, 67
Float-charging 27
Flushing the Exhaust Heat Exchanger 75
Fuel filter cleaning 53
Fuel level checking 49
Fuel line 8, 9, 50
Fuel pump 3, 4, 5, 50, 53
Fuel type 6
Fuel valve 8, 9, 18, 19, 21, 50
Function of WhisperGen 1
Fuse 60, 64, 85
Gas pressure 6
General checking 48
Glow plug 8, 9, 62
Hazards 11
Heat management 30
Information structure 17
Installing WhisperGen 16
Keys on control panel 10
LCD contrast adjustment 35
LCD backlight adjustment 36
Maintenance 45
Maintenance schedule 45
Manual stopping 20
Maximum running time 22
Meaning of parameters 37
Nitrogen gas 6
93
R
Operating options 16
Operating time 22
Operation 16
Oxygen sensor 8, 9, 70
Parameters 37
Parameter settings 41, 43
Pump 3, 4, 5, 50, 53, 56
Quick reference 16
Remote controlling 25
Removing enclosure lid 47
Replacing evaporator 72
Replacing FID 67
Replacing fuses 64
Replacing glow plug 62
Replacing oxygen sensor 70
Resetting control panel 81
Resetting electronics hardware 81
Safety precautions 11
Schedule for maintenance 45, 46
Seawater pump 3, 5, 56
Specifications 6, 7
Starting WhisperGen 18, 19
Stirling-cycle engine 2
Stopping WhisperGen 20
Summary of options 16
Summary of parts 8, 9
System parameters 37
Temperature of coolant 30
Troubleshooting 78
Warning 32, 82
Warning clearing 32
Warning codes 82
Warning correcting 82
Wobble yoke mechanism 2
Working principle 1
1 …

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